CN103071923B - 一种激光透射复合连接方法 - Google Patents

一种激光透射复合连接方法 Download PDF

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CN103071923B
CN103071923B CN201210581878.XA CN201210581878A CN103071923B CN 103071923 B CN103071923 B CN 103071923B CN 201210581878 A CN201210581878 A CN 201210581878A CN 103071923 B CN103071923 B CN 103071923B
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laser
polymer
welding
metal
transmitting
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CN103071923A (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
范彩莲
李品
王霄
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Jiangsu University
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Jiangsu University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B29C65/1629—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/16—Laser beams
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
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    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/9221—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by measuring the pressure, the force, the mechanical power or the displacement of the joining tools by measuring the pressure, the force or the mechanical power
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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Abstract

本发明公开了一种激光透射复合连接方法，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电火花处理,在其表面形成凹坑，焊接时把表面经过电火花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电火花处理形成了凹坑，所以在焊接压力的作用下，表层熔化的聚合物流进凹坑，在焊缝处形成一种类似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。实本发明可广泛的应用于对连接强度要求较高的激光透射焊接领域。

Description

一种激光透射复合连接方法
技术领域
本发明属于激光透射焊接技术领域，特指一种激光透射复合连接的方法。用电火花处理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，从而促使金属与聚合物更好的相互结合，可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，实际应用中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,既可以满足实际生产中高强度、耐久性的需要，也可以减少成本的投入。目前国内外对于提高激光透射焊接连接强度的方法主要是优化其工艺参数。经检索：国外文献《EffectofanodizingonpulsedNd:YAGlaserjoiningofpolyethyleneterephthalate(PET)andaluminiumalloy(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，通过激光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，在焊缝处形成一种类似铆接结构的咬合界面，可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复合连接方法。根据激光透射焊接特点，用电火花处理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,从而促使金属与聚合物更好的相互结合,可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，用电火花加工机床在原始形貌金属表面加工形成直径为40um—500um，深度为50um—100um，相邻间距为2mm—5mm的凹坑；
B）焊件装配：将表面形成凹坑的电火花处理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，聚合物搭接在电火花处理后金属上，聚合物和电火花处理后金属紧密贴近，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，通过置于电火花处理后金属下的压力传感器测量压力数值；
C）焊接试验：用能量连续的激光器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。
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，提供了一种激光透射复合连接的方法，可以更好、更快、方便、安全、可靠的提高激光透射焊接连接强度，使得激光透射焊接领域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，一种激光透射复合连接的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为金属表面凹坑形貌图。
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电火花处理后金属，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原始形貌金属，13尼龙，14进入凹坑的尼龙，15304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13和304不锈钢15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，将其放在电火花加工机床的工作台上，采用标准电极直径250um的铜钨电极加工。根据实际材料的焊接区域位置进行处理，同时用乙醇清洗掉尼龙13表面的杂质，吹干后备用。选定加工参数：开路电压为90V，充电电阻为500欧姆，电容为470pF，工作液为去离子水，加工时间35s，可加工直径为250um，深度为100um，间距为2mm的单排凹坑。
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调节激光束功率为：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180mm/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4所示焊接后的形貌图。

Claims (3)

1.一种激光透射复合连接方法，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，用电火花加工机床在原始形貌金属（12）表面加工形成直径为40um—500um，深度为50um—100um，相邻间距为2mm—5mm的凹坑；所述原始形貌金属（12）为304不锈钢金属，所述原始形貌金属（12）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；
B）焊件装配：将表面形成凹坑的电火花处理后金属（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）搭接在电火花处理后金属（3）上，聚合物（4）和电火花处理后金属（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，通过置于电火花处理后金属（3）下的压力传感器（2）测量压力数值；所述聚合物（4）为透明的尼龙，用K9玻璃作为约束层；
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的激光透复合射焊接方法，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。
3.根据权利要求1的激光透射复合焊接方法，其特征在于，所述步骤A）中，所述电火花加工机床采用标准电极直径250um的铜钨电极，加工参数为：开路电压为90V，充电电阻为500欧姆，电容为470pF，工作液为去离子水，加工时间35s。
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