CN103009626A - 一种激光透射焊接连接方法 - Google Patents

一种激光透射焊接连接方法 Download PDF

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CN103009626A
CN103009626A CN2012105810190A CN201210581019A CN103009626A CN 103009626 A CN103009626 A CN 103009626A CN 2012105810190 A CN2012105810190 A CN 2012105810190A CN 201210581019 A CN201210581019 A CN 201210581019A CN 103009626 A CN103009626 A CN 103009626A
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laser
polymer
metal
transmitting
welding
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CN103009626B (zh
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刘会霞
赵振关
陈浩
黄创
严长
顾宇轩
张迪
马友娟
邱唐标
李品
王霄
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Jiangsu University
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
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    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
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Abstract

本发明公开了一种激光透射焊接连接方法，属于激光透射焊接技术领域，特指金属与聚合物的激光透射焊接。本发明先将金属材料需要焊接的表面进行微细超声电解复合加工处理，在其表面形成凹坑，焊接时把表面经过微细超声电解复合加工处理后的金属作为下层吸光材料，聚合物作为上层透光材料，采用搭接的连接形式，用约束层夹紧并施加焊接压力，使用半导体激光器进行激光透射焊接，使得表面温度快速达到上层聚合物的熔点，聚合物表面融化，由于下层金属表面经过微细超声电解复合加工处理形成了凹坑，所以在焊接压力的作用下，表层熔化的聚合物流进凹坑，在焊缝处形成一种铆接结构的咬合界面，可实现提高激光透射焊接的连接强度。

Description

一种激光透射焊接连接方法
技术领域
本发明属于激光透射焊接技术领域，特指一种能提高金属和聚合物激光透射焊接连接强度的方法。用微细超声电解复合加工的方法在金属表面形成凹坑，在进行激光透射焊接时熔化的聚合物受到焊接压力的作用流入凹坑，在焊缝处形成一种铆接结构的咬合界面，增加金属与聚合物的连接接触面积，从而实现提高激光透射焊接连接强度。
背景技术
目前，激光透射焊接技术在聚合物与聚合物、聚合物与金属等同种和异种材料的焊接加工领域得到广泛应用，其特点是:快速、非接触、精确、热影响区小等，焊接产品伴随着激光透射焊接技术的发展，越来越多的被应用于医学等领域、汽车工业，如文献《PET薄膜与316L不锈钢薄板激光透射连接实验研究》中，316L不锈钢薄板与聚合物经过激光透射焊接可以应用于医学中作为生物植入体，但其指出激光透射连接接头的质量有待进一步研究提高。
连接强度是焊缝质量的一个重要评价指标，通常可以用剥离强度和拉伸强度来衡量。随着技术的发展，汽车零部件、电子器件产品封装、医疗器械等对激光透射焊接连接强度提出了较高的要求。文献《PET薄膜与薄钛板激光透射连接》指出，激光透射焊接焊缝接触面上发生了反应，金属与聚合物依靠化学键合实现连接，但是仅仅依靠化学键，其强度并不能达到目前对封装等技术高强度、耐久性的要求，根据对工艺的研究可知，理论上是功率越大越好，实际上功率过大会破坏焊缝质量，并且激光功率过大会增加工业成本，这就需要在激光能量适中时寻找一种可以显著提高激光透射焊接连接强度的方法,以满足实际生产中高强度、耐久性的需要。目前国内外对于提高激光焊接连接强度的方法比较的多,但是提高激光透射焊接链接强度的方法还比较的少，主要是通过优化激光透射焊接的工艺参数来获得最优的透射焊接质量。经检索：国外文献《Effect of anodizing on pulsed Nd:YAG laser joining of polyethylene terephthalate (PET) and aluminium alloy (A5052)》中提出一种方法,其特点是:将A5052铝合金表面进行阳极氧化,形成一层阳极氧化层,在激光透射焊接时用来吸收更多的激光能量,从而形成更深层次的熔池,实现激光透射焊接连接强度的提高。文献《激光冲击表面强化对焊接接头力学性能的影响》表述了一种对焊接接头的表面强化处理提高拉伸强度的方法，此方法是在焊接后再进行焊接连接强度的提高，在透射焊接中不可避免的会造成焊接后焊缝的破坏。而本发明针对金属与聚合物的材料特点，通过微细超声电解处理改变金属材料表面形貌，在金属表面形成有利于提高对激光吸收的凹坑，激光透射焊接时,能够使得金属表面快速升温,聚合物快速融化,在焊接压力的作用下，熔化的聚合物进入凹坑中，在焊缝处形成一种铆接结构的咬合界面，从而提高了激光透射焊接连接强度，尤其是拉伸强度。
发明内容
本发明的目的是提供一种激光透射焊接连接的方法。根据激光透射焊接特点，用微细超声电解复合加工的方法在吸收层金属材料的表面形成凹坑，在焊接时使得受到焊接压力作用的熔化聚合物流进凹坑,在焊缝处形成一种类似铆接结构的咬合界面,增加金属与聚合物的连接接触面积，实现提高激光透射焊接连接强度。
本发明的具体步骤为：
A）形成凹坑：将表面平整的原始形貌金属用乙醇进行超声波清洗，清除其表面杂质，吹干后，用精密加工机床在原始形貌金属表面加工形成直径0.480mm—0.510mm，深度为0.08mm—0.120mm，间距为2mm—5mm的凹坑；
B）焊件装配：将表面形成凹坑的微细超声电解后金属作为下层吸光材料，聚合物作为上层透光材料放在工作台上，聚合物搭接在微细超声电解后金属上，聚合物和微细超声电解后金属紧密贴近，中间没有间隙，约束层置于聚合物上，压板置于约束层上，通过放置在压板上的压头施加焊接压力，通过置于微细超声电解后金属下的压力传感器测量压力数值；
C）焊接试验：用能量连续的激光发生器对约束层进行激光透射，激光束的能量、激光光斑大小由激光器控制计算机调节和控制，激光束透过约束层和聚合物使金属表面温度快速达到上层聚合物的熔点，聚合物表面融化，聚合物受到压头施加的焊接压力，聚合物的表层熔化并流进凹坑，在焊缝处形成铆接结构的咬合界面，控制装置控制工作台沿X方向移动，调节工件与激光束的相对位置。其中被处理的金属可根据实际材料焊接区域的位置及宽度选择凹坑的位置和行列数，同时选择凹坑的深度要参考实际焊接金属材料的厚度。
本发明中金属与聚合物连接的形式采用搭接，即：金属在下面，聚合物置于金属之上，金属与聚合物有一定的重合接触区域。
本发明的实现，可以更好、更快、方便、安全、可靠的显著提高激光透射焊接连接强度，使得提高激光透射焊接连接强度领域得到突破，不再受限于依靠传统的优化工艺参数方法来获得高强度的焊缝该方法使得金属与聚合物的局部连接更加的牢固，在医学和光电子领域获得封装的耐久性, 在汽车等连接强度要求很高的领域实现构件连接的应用。本发明通过显著提高激光透射焊接的连接强度推动激光透射焊接技术在工业上的应用。
附图说明
图1为焊接材料的连接形式示意图。
图2为本发明焊件装配及原理图。
图3为金属凹坑的形貌图。
图4为实施例焊接后的剖面图。
图中，1 计算机，2 压力传感器，3微细超声电解后金属，4聚合物，5 约束层，6 压板，7 激光发生器，8 压头， 9 工作台， 10工作台控制装置，11 凹坑，12 金属原始形貌，13 尼龙， 14进入凹坑的尼龙，15  304不锈钢。
具体实施方式
下面结合具体实施例对本发明进一步说明，用本发明焊接透明的尼龙和304不锈钢金属。
焊件准备: 选择的焊接透明透光材料尼龙13尺寸为10x10x2mm，吸光材料304不锈钢15尺寸为10x10x0.6mm。激光透射焊接激光器采用的是能量连续的半导体激光发生器7，最大功率为130w，波长为980nm±10nm。
焊件的表面处理: 将样品304不锈钢15用乙醇进行超声波清洗,去掉其表面杂质，吹干后，将其放在精密加工机床工作台上，选用Φ0.5mm圆形微细轴工具电极，应用电解液为 5%硝酸钠水溶液，选定工件与工具间静压力为 2.0N，加工时间 2min，磨料 W10 碳化硼,，磨料悬浮液浓度 15%，采用“静液”方式定时供给电解液，脉冲频率5000Hz，脉冲占空比 3:7，脉冲电压为3V，获得凹坑直径0.492mm，深度为0.094mm，凹坑间距为2mm。处理完后用乙醇进行清洗，除去金属表面电解介质，同时用乙醇清洗掉尼龙13表面的杂质，吹干后备用。 
焊件的装配及焊接: 将步骤2得到的304不锈钢15放在半导体激光器的工作台9上作为下层吸光材料，尼龙13作为上层吸光材料，通过激光发生器控制计算机1调节功率为：60w，光斑直径为2mm。尼龙13和304不锈钢15采用如图1所示的搭接连接形式，尼龙13和304不锈钢15紧密贴近，中间没有间隙，用K9玻璃作为约束层，在约束层玻璃上放置压板6并在压板上用压头8施加焊接压力0.069KN，激光器按照120mm/min速度进行激光透射焊接，激光透射焊接时通过工作台控制装置10实现工件沿X方向移动，用于调整工件与激光束的相对位置。
形成高强度的焊接接头,对焊缝分析可看到进入凹坑的尼龙14，如图四所示焊接后的形貌图。

Claims (5)

1.一种激光透射焊接连接方法，其特征在于，具体步骤为：
A）形成凹坑：将表面平整的原始形貌金属（12）用乙醇进行超声波清洗，清除其表面杂质，吹干后，用精密加工机床在原始形貌金属（12）表面加工形成直径0.480mm—0.510mm，深度为0.08mm—0.120mm，间距为2mm—5mm的凹坑；
B）焊件装配：将表面形成凹坑的微细超声电解后金属（3）作为下层吸光材料，聚合物（4）作为上层透光材料放在工作台（9）上，聚合物（4）搭接在微细超声电解后金属（3）上，聚合物（4）和微细超声电解后金属（3）紧密贴近，中间没有间隙，约束层（5）置于聚合物（4）上，压板（6）置于约束层（5）上，通过放置在压板（6）上的压头（8）施加焊接压力，通过置于微细超声电解后金属（3）下的压力传感器（2）测量压力数值；
C）焊接试验：用能量连续的激光发生器（7）对约束层（5）进行激光透射，激光束的能量、激光光斑大小由激光器控制计算机（1）调节和控制，激光束透过约束层（5）和聚合物（4）使金属表面温度快速达到上层聚合物（4）的熔点，聚合物（4）表面融化，聚合物（4）受到压头（8）施加的焊接压力，聚合物（4）的表层熔化并流进凹坑（11），在焊缝处形成铆接结构的咬合界面，控制装置（10）控制工作台（9）沿X方向移动，调节工件与激光束的相对位置。
2. 根据权利要求1的一种激光透射焊接连接方法，其特征在于，所述步骤A）其中被处理的金属可根据实际材料焊接区域的位置及宽度选择凹坑的位置和排数。
3. 根据权利要求1或2的激光透射焊接连接方法，其特征在于，所述步骤B）中，所述约束层（5）对于所应用激光是透明的，激光束透过时无明显能量损失。
4. 根据权利要求1或2的激光透射焊接连接方法，其特征在于，所述聚合物（4）为透明的尼龙，所述原始形貌金属（11）为304不锈钢金属，用K9玻璃作为约束层。
5. 根据权利要求4的激光透射焊接连接方法，其特征在于，所述步骤A）中，所述精密加工机床选用Φ0.5mm圆形微细轴工具电极，电解液为 5%硝酸钠水溶液，微细超声电解后金属（3）与工具电极间静压力为 2.0N，加工时间为 2min，磨料为 W10 碳化硼，磨料悬浮液浓度为以质量计 15%，采用“静液”方式定时供给电解液，脉冲频率为5000Hz，脉冲占空比为 3:7，脉冲电压为3V。
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