CN104668765B - 一种消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法 - Google Patents
一种消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法 Download PDFInfo
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/16—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas
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- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
- B23K20/2333—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer one layer being aluminium, magnesium or beryllium
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Abstract
本发明提供了一种消除镁合金搅拌摩擦搭接接头中(包括点焊和线焊)钩状缺陷(Hook defects)的焊接方法,属于镁合金焊接技术领域。该方法通过在被焊接的上下层镁合金板之间预置低熔点金属或合金夹层,利用轴肩摩擦产生的压力与热量促使夹层与镁合金发生反应,在接头热影响区和热机影响区内生成新型结合区,从而避免钩状缺陷的形成,达到提高焊接接头力学性能的目的。
Description
技术领域
本发明涉及镁合金焊接领域,特别涉及一种消除镁合金搅拌摩擦搭接接头(点焊或线焊)钩状缺陷的方法。
背景技术
镁合金由于具有密度低、比强度高、阻尼减震性好、机械加工容易以及可回收性好等一系列优点,在航空航天、汽车等行业具有极其重要的应用价值和广阔的应用前景。
然而由于镁的塑性变形能力差,因而目前的镁合金产品多为铸件。近年来,随着汽车、高速列车、大型飞机、航天飞行器、武器等装备制造业的快速发展,变形镁合金发展迅速,实现其可靠连接的重要性日益凸显。虽然熔化焊是金属材料连接的主要方法,但是由于镁元素极为活泼,因此在其熔化焊时易产生夹杂、气孔和脆性相等缺陷,并伴有晶粒粗化、结晶偏析、热裂纹等问题。
搅拌摩擦焊是一种新型固相焊接技术,是世界焊接技术发展史上自发明到工业应用时间跨度最短且发展最快的一项连接技术,被誉为“世界焊接史上的第二次革命”。搅拌摩擦焊是一种连续、纯机械的连接技术,其工作原理如下:在焊接过程中,由轴肩和搅拌针组成的搅拌头一边高速旋转一边将搅拌针挤入待焊工件的接缝处,直至轴肩与工件紧密接触,然后搅拌头沿接缝处旋转移动,搅拌区经剧烈塑性变形产生温升、软化,实现固相连接。搅拌针的作用是搅动接缝两侧的材料,使其产生塑性流变和混合;轴肩的作用是摩擦生热,把由搅拌针搅动变形的材料传输到搅拌头后侧并同时施加锻造作用,从而形成密实无缺陷的焊缝。因此搅拌摩擦焊接可有效避免由熔化—凝固过程所引起的焊接缺陷,接头力学性能优异,是镁合金连接的理想方法。
搅拌摩擦焊可实现对接、搭接(包括点焊和线焊)等形式的焊接。搭接结构是最常用焊接结构之一。现有研究报导表明,镁合金在搅拌摩擦搭接焊过程中,包括点焊(Journalof Materials Processing Technology,Vol.210,(2010)p2062-2070)和线焊(Scienceand Technology of Welding and Joining,Vol.15,No.5(2012)p375-360),均会形成钩状缺陷(Hook defects),在受力过程中极易导致接头中的裂纹扩展甚至断裂(焊接学报,Vol.32,(2011)p101-104),降低接头的可靠性。
目前的研究表明,夹层在异种金属的搅拌摩擦焊接中会起到改善接头质量的作用,例如专利(申请号:201210307178.1)采用熔点介于高熔点与低熔点母材之间的夹层,在搅拌针作用下,搅拌区的夹层熔化并与低熔点母材形成熔化连接,而其中高熔点母材并不熔化,因而在界面处形成钎焊连接;专利(申请号:201210307205.5)采用添加夹层的方式,通过不断移动的搅拌头作为热源,还可以安装移动的热源起到在焊接过程中的保温作用,实现夹层合金与熔点不同的两种母材之间的瞬时液相扩散连接。需要指出的是,上述专利均是利用搅拌针作用,促使搅拌区熔化的夹层与异种金属之间反应,形成新型金属间化合物,实现不同材料之间的钎焊或者扩散焊连接。
专利(申请号:201210592060.8),采用锡做夹层,通过搅拌摩擦焊技术实现镁-铝异种金属的焊接,夹层起到了阻碍镁-铝金属间化合物生成的作用。该研究主要利用了搅拌针在搅拌区产生的热机作用,使锡夹层熔化并与镁和铝合金在搅拌区形成合金化反应,从而减弱了镁-铝金属间化合物的生成,实现镁-铝异种金属的焊接。
对于异种材料的焊接而言,由于搅拌区连续分布的金属间化合物是决定接头性能的关键因素,因此其研究是以合金化反应为核心、利用夹层金属熔化,阻止或促进异种金属在搅拌区的直接反应,实现提高接头性能的目的。
由此可见,目前添加夹层的研究主要是针对异种金属的搅拌摩擦焊接,没有涉及到同种金属,更没有涉及到对搭接接头中钩状缺陷的控制。然而,对于同质镁合金焊接而言,接头在搅拌区并不存在连续分布的金属间化合物,搅拌区强度较高,但是接头中穿过热影响区终止于热机影响区的钩状缺陷,作为裂纹萌生的潜在区,影响接头性能。虽然目前的研究(Journal of Materials Processing Technology,Vol.210,(2010)p2062-2070;Science and Technology of Welding and Joining,Vol.15,No.5(2012)p375-360)通过改善钩形缺陷的宽度、角度及其顶端到接头上表面之间的距离等方式在一定程度上改善了接头性能,但是未能从根本上消除钩状缺陷对裂纹敏感性较强的镁合金焊接接头性能的影响。
发明内容
为解决现有技术中镁合金搅拌摩擦搭接焊接过程中容易产生钩状缺陷,接头质量难以保证的问题,本发明提供一种消除镁合金搅拌摩擦搭接接头钩状缺陷的搅拌摩擦焊接方法。
为了达到上述目的,本发明所采用的技术方案是:
一种消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法,该方法首先在待焊接的上下镁合金板之间预置夹层,然后进行搅拌摩搭接焊(点焊或线焊),通过夹层与镁合金之间的扩散反应消除钩状缺陷。
所述夹层为低熔点的锌、锡或锌-锡合金(锌含量5-40wt%,其余为锡)材质,厚度范围为10-200μm。
所述预置夹层的方式为:采用喷涂或粘结的方式在上下镁合金板之间制备;或者,夹层材料直接以箔片状方式放置在上下镁合金板之间。
焊接过程中,搅拌头转速为1000-3000r/min,搅拌针长度大于上层镁合金板材厚度和夹层的厚度之和;轴肩压入量控制在上层镁合金板材厚度的1/6-5/6,但搅拌针插入下层镁合金板材的深度不超过下层镁合金板材厚度的5/6,轴肩直径至少大于搅拌针直径1倍。
本发明优点如下:
1、本发明采用在镁合金上下板之间预置低熔点金属或合金夹层的方式,利用轴肩的热机作用,在接头热影响区和热机影响区内形成新型合金区,消除接头中钩状缺陷,达到提高接头性能的目的。
2、本发明提出的镁合金搭接接头钩状缺陷的消除方法,具有工艺装配和焊接过程简单、可显著提高接头可靠性的特点,因而具有广阔的工业应用前景。
附图说明
图1是本发明中夹层预置位置区域以及搅拌针作用位置的示意图。
图2是预置锡夹层的点焊接头左半区金相图;其中:(a)宏观和(b)新型合金化区的放大组织。
图3是预置锌夹层的点焊接头的左半区金相图;其中:(a)宏观和(b)新型合金化区的放大组织。
图4是涂覆锌-锌合金夹层(锌含量5-40%,其余为锡)的点焊接头的左半区金相图;其中:(a)宏观和(b)新型合金化区的放大组织。
图5是常规镁合金搅拌摩擦点焊接头金相图;其中:(a)宏观和(b)放大的钩状缺陷。
图6是预置锌夹层的搭接缝焊接头的左半区金相图;其中:(a)宏观和(b)新型合金化区的放大组织。
图7是常规镁合金搅拌摩擦搭接缝焊接头的金相图;其中:(a)宏观(b)放大的钩状缺陷。
图中:1-上层镁合金板材;2-下层镁合金板材;3-夹层;4-轴肩;5-搅拌针;H1-上层镁合金板厚;H2-下层镁合金板厚;H3-夹层厚度;D1-搅拌针直径;D2-轴肩直径。
具体实施方式
下面结合附图及实施例对本发明作进一步详细说明。
本发明中夹层预置位置区域以及搅拌针作用位置的示意图如图1所示。本发明是在待焊接的上下镁合金板之间预置夹层3,然后进行搅拌摩搭接焊,搅拌针5插入下层镁合金材2的厚度H2的1/6-5/6处,同时在轴肩4的热机作用下,夹层3与搅拌针直径D1以外至轴肩直径D2以内环形区域内的镁合金(上层镁合金材1和下层镁合金材2)发生反应,在接头热影响区和热机影响区内形成新型结合区,消除接头中钩状缺陷。
实施例1
将2.4mm厚镁合金板材进行搭接装配,在上下板之间预置0.1mm厚的锡夹层,然后进行常规搅拌摩擦点焊(针直径3mm,轴肩10mm,针长1.8mm,转速3000r/min,停留时间5s)。微观组织分析以及力学性能测试显示,接头中没有出现钩状缺陷(如图2所示),取而代之的是锡与镁合金作用形成的Sn-Mg合金区,点焊接头抗拉载荷约为3.0kN。
实施例2
将2.4mm厚镁合金板材进行搭接装配,在上下板之间预置0.2mm厚的锌夹层,进行常规搅拌摩擦点焊(针直径3mm,轴肩10mm,针长1.8mm,转速3000r/min,停留时间5s)。微观组织分析显示,接头中无钩状缺陷(如图3所示),取而代之的是锌与镁合金扩散反应形成的Zn-Mg合金区。力学性能测试表明点焊接头抗拉载荷约为4.0kN。
实施例3
将2.4mm厚镁合金板材进行搭接装配,在上下板之间涂覆0.1mm厚的锌-锡合金(锌含量5wt%,其余为锡)夹层,进行常规搅拌摩擦点焊(针直径3mm,轴肩10mm,针长1.8mm,转速3000r/min,停留时间5s)。微观组织分析显示,接头中无钩状缺陷(如图4所示),取而代之的是锌-锡合金与镁合金扩散反应形成的Zn-Sn-Mg三元合金区。力学性能测试表明点焊接头抗拉载荷约为3.4kN。
对比例1
将2.4mm厚镁合金板材进行搭接装配,进行搅拌摩擦点焊(针直径3mm,轴肩10mm,针长2.8mm,转速3000r/min,停留时间5s)。微观组织分析以及力学性能测试显示,接头中出现明显的钩状缺陷(如图5所示),抗拉载荷约为2.3kN。
实施例4
将2.0mm厚镁合金板材进行搭接装配,在上下板之间预置0.18mm厚的锌夹层,然后进行常规搅拌摩擦线焊(针直径6mm,轴肩16mm,针长2.8mm,转速3000r/min,焊接速度500mm/min)。微观组织分析以及力学性能测试显示,接头中没有出现钩状缺陷(如图6所示),取而代之的是锌与镁合金作用形成的Zn-Mg合金区,达到了消除钩状缺陷的目的。
对比例2
将2.0mm厚镁合金板材进行搭接装配,直接进行常规搅拌摩擦线焊(针直径6mm,轴肩16mm,针长2.8mm,转速3000r/min,焊接速度500mm/min)。微观组织分析显示,接头中出现了明显钩状缺陷(如图7所示)。
以上提供的实施例仅仅是解释说明的方式,不应认为是对本发明的范围限制,任何根据本发明的技术方案及其发明构思加以等同替换或改变的方法,都应涵盖在本发明的保护范围之内。
Claims (4)
1.一种消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法,其特征在于:该方法首先在待焊接的上下镁合金板之间预置夹层,然后进行搅拌摩搭接焊,通过夹层与镁合金之间的扩散反应消除钩状缺陷;所述夹层为低熔点的锌、锡或锌-锡合金材质,所述锌-锡合金中,锌含量5-40wt%,其余为锡;
所述搅拌摩搭接焊工艺参数为:搅拌头转速为1000-3000r/min,搅拌针长度大于上层镁合金板材的厚度和夹层的厚度之和;轴肩压入量控制在上层镁合金板材厚度的1/6-5/6,搅拌针插入下层镁合金板材的深度不超过下层镁合金板材厚度的5/6,轴肩直径至少大于搅拌针直径1倍。
2.如权利要求1所述的消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法,其特征在于:所述夹层的厚度范围为10-200μm。
3.如权利要求1所述的消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法,其特征在于:所述预置夹层的方式为:采用喷涂或粘结的方式在上下镁合金板之间制备;或者,夹层材料直接以箔片状方式放置在上下镁合金板之间。
4.如权利要求1所述的消除镁合金搅拌摩擦搭接接头钩状缺陷的焊接方法,其特征在于:所述搅拌摩搭接焊为点焊或线焊。
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CN114029603A (zh) * | 2021-08-13 | 2022-02-11 | 榆林学院 | 一种镁合金薄板高速搅拌摩擦焊接夹持装置及焊接方法 |
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