CN107414291B - 超声辅助激光焊接异种材料 - Google Patents

超声辅助激光焊接异种材料 Download PDF

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Publication number
CN107414291B
CN107414291B CN201710313377.6A CN201710313377A CN107414291B CN 107414291 B CN107414291 B CN 107414291B CN 201710313377 A CN201710313377 A CN 201710313377A CN 107414291 B CN107414291 B CN 107414291B
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laser
workpiece
welding
sheet
polymer material
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CN201710313377.6A
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CN107414291A (zh
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陈玉娇
余大民
郭钟宁
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Guangdong University of Technology
Hong Kong Polytechnic University HKPU
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Guangdong University of Technology
Hong Kong Polytechnic University HKPU
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B23K26/324—Bonding taking account of the properties of the material involved involving non-metallic parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/244—Overlap seam welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/50—Working by transmitting the laser beam through or within the workpiece
    • B23K26/57—Working by transmitting the laser beam through or within the workpiece the laser beam entering a face of the workpiece from which it is transmitted through the workpiece material to work on a different workpiece face, e.g. for effecting removal, fusion splicing, modifying or reforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
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    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • 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
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    • 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
    • B29C65/44—Joining a heated non plastics element to a plastics element
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    • 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
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • 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
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • 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
    • 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
    • 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
    • B29C66/342—Preventing air-inclusions
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • 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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • 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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—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
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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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    • B29C66/70—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
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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
    • B29C66/70—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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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    • B29C2035/0838—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using laser
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    • B29C65/82—Testing the joint
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    • B29C65/8215—Tensile tests

Abstract

一种用于将第一材料焊接到第二材料的激光焊接系统及其方法，该系统包括激光器、超声振动装置和夹紧装置，在激光焊接金属和塑料时，在焊接部位施加超声振动，相比传统的激光辅助金属和塑料(LAMP)连接方法，该方法能够消除焊缝区域由激光加热导致高分子材料降解生成的气泡并且提高焊接强度。

Description

超声辅助激光焊接异种材料
技术领域
本发明涉及焊接系统及方法，更具体地说，涉及一种适用于焊接异种材料的超声辅助激光焊接系统及方法。
背景技术
在说明书中引用了以下参考文献。这些参考文献的公开内容通过引用整体并入本文。
参考文献：
[1]M.Grujicic,V.Sellappan,M.A.Omar,Norbert Seyr,Andreas Obieglo,MarcErdmann,Jochen Holzleitner,An overview of the polymer-to-metal direct-adhesion hybrid technologies for load-bearing automotive components,Journalof Materials Processing Technology 197(2008)pp.363–373.
[2]T.Sutana,G.L.Georgiev,R.J.Baird,G.W.Auner,G.Newaz,R.Patwa,H.J.Herfurth,Study of two different thin film coating methods in transmissionlaser micro-joining of thin Ti-film coated glass and polyimide for biomedicalapplications,Journal of the Mechanical Behavior of Biomedical Materials 2(3)(2009)pp.237–242.
[3]S.T.Amancio-Filho,J.F.dos Santos,Joining of polymers and polymers–metal hybrid structures:Recent developments and trends,Polymer Engineeringand Science 49(8)(2009)pp.1461–1476.
[4]S.Katayama,Y.Kawahito,Laser direct joining of metal andplastic.Scripta Materialia 59(12)(2008)pp.1247-1250.
[5]S.Katayama,Laser joining of metal and plastic,Industrial LaserSolutions,11/01/2010.http://www.industrial-lasers.com/articles/print/volume-250/issue-6/feature s/laser-joining-of-metal-and-plastic.html
[6]Y.Kawahito,K.Nishimoto,S.Katayama,LAMP joining between ceramic andplastic,Physics Procedia 12(2011)pp.174–178.
[7]Y.Kawahito,Y.Niwa and S.Katayama,Laser direct joining betweenstainless steel and polyethylene terephthalate plastic and reliabilityevaluation of joints,Welding International 28(2)(2014)pp.107–113.
[8]Y.Farazila,Y.Miyashita,W.Hua,Y.Mutoh,Y.Otsuka,YAG laser spotwelding of PET and metallic materials,Journal of Laser Micro/Nanoengineering6(1)(2011)pp.69-74.
[9]M.Wahba,Y.Kawahito,S.Katayama,Laser direct joining of AZ91Dthixomolded Mg alloy and amorphous polyethylene terephthalate,Journal ofMaterials Processing Technology 211(6)(2011)pp.1166–1174.
[10]I.Jones,Laser welding for plastic components,Assembly Automation22(2)(2002)pp.129-135.
[11]G.
Figure BDA0001287777370000021
M.
Figure BDA0001287777370000022
Progress in joining of advanced materials,Internatioanl Materials Reviews 43(1)(1998)pp.1-44.
[12]A.Roesner,S.Scheik,A.Olowinsky,A.Gillner,R.Poprawe,M.Schleser,U.Reisgen,Innovative approach of joining hybrid components,Journal of LaserApplications 23(3)(2011)Article no.032007.
[13]R.Y.Yeh,R.Q.Hsu,Development of ultrasonic direct joining ofthermoplastic to laser structured metal,International Journal of Adhesion andAdhesives 65(2016)pp.28-32.
近年来，不同种类材料(例如轻金属和高分子材料)之间的连接越来越受重视，尤其是在汽车工业和生物医学领域。考虑到节能和环保等相关问题以及对轻质产品高性能的要求，对在同一产品中同时使用异种材料和复合材料的需求显得尤为突出。实际上，许多汽车和生物医学产品都是由多种高分子材料(或塑料)和轻质金属(或金属合金/陶瓷)组合制成，这样可以充分发挥不同类型材料的优点。但是事实上，由于高分子材料与金属的物理及化学性能存在着较大的差异，导致使用传统常规的焊接方法很难获得质量可靠的焊缝。传统连接高分子材料与金属的方法包括粘合剂粘合，螺钉或铆钉的机械紧固。然而，这些传统技术都存在着不可避免的缺点。粘合剂连接效率低及产生易挥发性有机化合物。至于机械紧固，不灵活的设计是它的主要缺点。为了规避这些问题，Katayama，已经开发了一种激光焊接技术，用于直接焊接金属与高分子材料(塑料)，即激光辅助金属和塑料焊接(LAMP)。事实上，LAMP也适用于陶瓷与高分子材料(塑料)的连接。该想法比较直接，它使用激光来加热金属与高分子材料界面，要么用激光透过高分子材料在界面处产生热量，要么使激光器加热金属部件并且通过热传导加热界面处的高分子材料(图1)。在这两种情况下，界面处的高分子材料(塑料)都会发生熔化并部分分解，并且残留在再次固化的高分子(塑料)区域中。通常认为，激光加热使高分子材料(塑料)发生降解导致气泡的生成，气泡的快速膨胀将熔融的高分子材料(塑料)挤向金属的一侧，使熔融高分子材料(塑料)与金属表面紧密接触。结果，在机械上获得很强的锚固效应，同时在金属和高分子材料(塑料)之间形成很强的化学粘合。
实际上，LAMP已经用于快速生产能够商业应用的金属合金/陶瓷和工程塑料之间的强连接。目前的研究结果表明，尽管LAMP能够获得抗拉强度较高的焊缝，但是在焊缝中存在着由激光引起的气泡削弱了焊缝在使用过程的强度和疲劳性能。虽然在焊接过程中气泡的膨胀有助于促进金属和塑料之间形成紧密接触，但是当熔融塑料固化后，气泡将会被困在焊缝中，气泡的尺寸、数量和分布都直接影响着焊接接头的性能。而且，到目前为止，仍然没有可用于将激光引起的体积较大的气泡分散成较小气泡或完全将其消除的有效方法。
众所周知，激光和超声可以独立地用于高分子材料(塑料)与高分子材料(塑料)、金属与金属的焊接中。但是，目前并没有激光辅助超声焊接或者超声辅助激光焊接高分子材料(塑料)与金属/陶瓷的相关资。Yeh首先使用激光照射在金属的表面上烧蚀并产生微网格阵列，然后将处理过的金属和塑料作为搭接接头放在一起并使用超声波加热熔化塑料，使塑料固化后形成焊接接头。在这个例子中，尽管使用激光和超声两种工艺，但它不是激光和超声波的联合作用，并且激光照射和超声波振动的功能与本发明所述存在着根本差异。
发明内容
本发明提出了一种使用激光和超声波联合作用的新型超声波辅助激光焊接异种材料(金属或金属合金/陶瓷材料与高分子材料(塑料)的连接)的方法(UAL)，该方法可以解决LAMP中的气泡问题。实验证明，该方法利用超声波振动可以有效地减少焊缝区域的气泡数量及体积，在特定实验参数下，甚至可以完全消除气泡并且获得抗拉强度足够高的焊缝。
本发明的第一方面是提供一种用于焊接两种异种材料的激光焊接系统。
根据本发明的一个实例，一种用于将第一种材料焊接到第二种材料的激光焊接系统包括：至少能发射一束激光束的激光系统，用于照射在待焊接工件上，该工件的组成是以搭接的方式将第一种材料置于所述第二种材料之上而形成；超声振动装置，该装置能够在激光焊接过程中提供以超声波频率的振动，把振动的振幅转化为压力作用于待焊接工件上；以及夹紧装置，用于提供待焊工件之间的夹紧力；其中待焊接的第一和第二种材料之一能被激光束穿透过。
根据本发明的实例，一种用于将高分子材料(塑料)焊接到金属/陶瓷材料上的激光焊接系统包括：激光系统，用于发射至少一束激光束，用于照射于以搭接方式(即将第一种材料放置在第二种材料上)所组成的工件上；振动装置，能够以超声波频率振动，并将振动的振幅转化为压力作用于工件上；以及用于通过向工件施加夹紧力来夹紧工件的夹紧装置。
本发明的第二方面是提供了一种使用激光焊接系统来焊接两种异种材料的方法。
根据本发明的实例，使用本发明的系统将第一材料焊接到第二材料的方法包括：将第一材料以搭接的方式放置在第二材料上形成待焊接工件；通过所述夹紧装置夹紧所述待焊接工件；通过激光束照射所述工件；通过所述超声波振动装置的高频振动对所述工件施加压力；其中待焊接的第一和第二材料之一能被激光束透过。
根据本发明的实例，使用本发明的激光焊接系统实现高分子材料(塑料)与金属/陶瓷材料焊接的方法包括：将高分子材料(塑料)放置在金属/陶瓷材料上以形成待焊工件；通过所述夹紧装置夹紧所述工件；通过所述激光束照射所述工件；以及经由所述超声波振动装置对所述工件施加高频振动。
附图说明
在下文中参照附图更详细地描述本发明的实例，其中：
图1示出传统激光辅助塑料与金属焊接(LAMP)方法的示意图；(A)激光透射塑料，(B)激光照射加热金属部件。
图2A示出超声辅助激光焊接塑料与金属(UAL)焊接系统，图2B示出超声波振动装置和夹持装置的横截面图，图2C示出超声波振动装置的放大示意图，图2D示出根据本发明的实例系统操作视图。
图3示出实例1中LAMP和UAL焊接样品的典型焊缝外观与激光功率的关系。
图4示出实例1中焊缝界面截面图：(A)LAMP焊接样品和(B)UAL焊接样品(激光功率55W，频率20Hz，焊接速度4mm/s)。
图5示出实施例1中由LAMP生产的PET/Ti样品经离子去除到不同深度之后的Ti侧的高分辨率XPSC1s图谱。
图6示出实例1中由UAL生产的PET/Ti样品经离子去除到不同深度之后的Ti侧的高分辨率XPSC1s图谱。
图7示出实例1中由LAMP和UAL生产的焊接样品的典型载荷-位移曲线(激光功率55W，脉冲频率20Hz，行进速度4mm/s)。
图8示出实例1中LAMP焊接样品的失效外观。
图9示出实例1中UAL焊接样品的失效外观。
图10示出实例1中激光功率对失效载荷(激光脉冲频率20Hz，焊接速度4mm/s)的影响。
图11示出实例2中由LAMP和UAL方法生成的典型焊缝外观(使用30W的低激光功率生产)。
图12示出实例2中由LAMP和UAL方法生产获得的焊缝的典型负载-位移曲线(使用30W的低激光功率生产)。
图13比较了实例2中LAMP和UAL方法生产获得的样品的失效载荷(使用30W的低激光功率制造)。
图14示出实例2，由LAMP生产的PET/Ti样品经离子去除到不同深度之后的Ti侧的高分辨率XPSC1s图谱。
图15示出实例2，由UAL生产的PET/Ti样品经离子去除到不同深度之后的Ti侧的高分辨率XPSC1s图谱。
具体实施方式
在下面的描述中，提出了用于焊接两种异种材料的超声辅助激光焊接系统和相应的操作方法，并用实例加以说明。对于本领域技术人员显而易见的是，在不脱离本发明的范围和内容的情况下，可以方便地进行修改，包括添加和/或替换，也可能省略特定细节，以概括说明本发明；然而，本发明所述内容是为了使本领域技术人员能够实施本发明的教导而无需过多的实验。
本发明提出了一种用于将高分子材料(塑料)与非高分子材料(特别是金属和陶瓷)焊接起来的新的超声波辅助激光焊接方法(UAL)，该方法可以消除激光产生的气泡并且能够显著改善焊接强度。
UAL系统是指待焊接的工件在激光照射的情况下，同时作用超声振动。该系统由激光器、超声波振动装置和工件夹紧装置组成(图2A)。并且超声装置可以沿着焊接方向移动，形成连续焊接接头。与传统的LAMP焊接方法类似，激光透过高分子材料(塑料)到达非高分子材料表面并对其进行加热(图1A)，这将导致界面处的高分子材料熔化；或激光直接照射于非高分子材料表面(图1B)，然后通过热传导的方法将金属表面的热量传递到界面处的高分子材料使其受热发生熔化或降解。
在UAL中，超声波用于(i)消除激光产生的气泡(ii)增强高分子材料和金属或者陶瓷之间的化学结合。从而增强两种材料之间的焊接强度。
如图2A所示，超声辅助激光焊接系统包括激光器101、超声振动装置102和夹紧装置103。由夹紧装置103夹持的工件109位于激光器101和超声振动装置102之间。激光器101包括用于聚焦激光束的激光头104。激光器101可以是脉冲激光器或连续激光器。超声波振动装置102由振动发生器105给电和控制。如图2B所示，夹紧装置包括夹紧气缸106、可移动板107和能透过激光束(本实例中采用石英玻璃)的固定顶板108。夹紧气缸106与可移动板107连接。工件109放置在可移动板107和顶板108之间。激光束可以透过顶板108照射在工件109上。可移动板107可以改变工件109的位置，并且当工件109与顶板108接触时，将力施加在工件109上。如图2C所示，超声振动装置102包括压电陶瓷换能器110、变幅杆111(以将振动能量从换能器传递到工件109)。变幅杆111附接到换能器110。开槽117位于变幅杆111的表面上。如图2D所示，在操作期间，包括待焊接的非高分子材料(金属或陶瓷)片112和高分子材料(塑料)片113的工件109(塑料片113放置在非塑料片112上，反之亦然)位于变幅杆111的顶表面上通过夹紧装置103提供作用在待焊接工件109上的夹紧力116。从激光头104出来的激光束114照射在工件109上。在高分子材料(塑料)片113与非高分子材料片(如金属或陶瓷)112的焊接过程中，由超声波振动装置102产生的超声波振动115作用于工件109上(113和112的位置可以互换)。
实例1
在本发明中，实例1选取聚对苯二甲酸乙二醇酯(PET)和钛(Ti)作为焊接材料用于LAMP和UAL焊接实验对比。钛及其合金广泛应用于航空航天和医疗设备中。PET是要焊接到Ti的塑料材料，它是医疗器械的重要材料，其化学式为(C10H8O4)n。待焊接的Ti(1mm厚，纯度99.6％)和PET(1mm厚，无定形)的尺寸都是60mm×25mm×1mm(长宽厚)。使用金刚石砂纸抛光钛样品的焊接面，并且在激光焊接之前，用乙醇在超声波清洗机中清洗所有的Ti和PET样品10分钟。
UAL焊接是使用专门设计的超声辅助激光焊接系统进行的(图2A-2D)。该系统主要由300W脉冲激光器、能够以28kHz的频率振动的超声波振动装置和夹紧装置组成。超声波振动装置包括一个表面上具有开槽结构的变幅杆(图2C)，工件搁置在开槽的变幅杆上。与具有平整表面的变幅杆相比，带有开槽的变幅杆对于去除气泡更有效。夹紧装置由顶部石英板、可移动板和两个气缸组成，激光束透过顶部石英板照射到工件上，两个气缸提供工件夹紧力。PET板以搭接的方式放置在钛板的上面形成待焊接工件。
激光束穿过能透过激光的固定顶板(在该实例中为石英板)和PET片，并且到达钛板上表面，由于Ti片对激光能量的吸收转换为热能，这导致被焊区域与钛板接触的PET板受热发生熔化并在一定程度上发生降解。搭接接头仅使用一次激光照射来焊接。
在激光焊接过程中，超声波振动装置的加载时间占总焊接时间的20％。本研究中使用的其他UAL焊接参数列于表1中。
表1 UAL焊接参数
Figure BDA0001287777370000081
使用X射线光电子能谱仪(XPS)分析Ti/PET焊缝区域界面处的化学状态。为了进行分析，通过机械的方法在界面处分离LAMP和UAL焊接的样品，并且使用XPS分析仪在Ti部分上进行分析。在C1s线的基础上使用软件对焊接界面上形成化学键的数量进行半定量分析。采用Ar离子溅射去除材料到不同深度，并且在每个特定去除深度处，对其进行XPS分析。
使用万能材料试验机来测量激光焊接样品的失效载荷。以0.5mm/min的速度进行测试，并记录失效载荷和位移曲线。进行一系列测试以研究各种激光加工参数对载荷-位移曲线的影响(包括LAMP和UAL的焊接样品)。为了降低人为误差，对于每组焊接参数，测试三个试样。
<焊缝外观>
使用光学显微镜观察所有的焊接试样。图3展示了激光功率和焊缝外观的关系。该图还比较了在使用相同的激光加工参数条件下，LAMP和UAL(有超声加载)生产的焊缝。结果显示，使用超声波振动(UAL)，气泡量显着减少，并且在大多数情况下，特别是当激光功率不超过55W时，在光学显微镜下几乎观察不到气泡。对焊接样品的横截面的检测显示，在LAMP焊接样品的界面处发现了许多气泡(图4A)，而在UAL焊接样品中几乎没有发现气泡(图4B)。照片还表明，对于LAMP方法，当激光功率增加时，气泡的数量及体积增加。
<XPS分析>
XPS检测结果(图5,6)显示，LAMP和UAL两种样品中都出现了Ti-C化学键，即C1s线中281.7eV处新峰出现的位置。这个新的峰被认为是由于Ti原子与苯基碳反应的结果。
对于LAMP焊接的样品，当深度达到1440nm时，Ti-C的能量峰值实际上已经消失了。这表明焊缝界面处含有新化学键Ti-C的LAMP样品厚度约为1440nm。对于UAL焊接的样品，发现总的Ti-C峰远高于LAMP样品(参见图5和图6)；图6还表明，同样在1440nm的深度，新化学键Ti-C的能量峰值仍然较强。
在相同激光参数条件下，UAL样品界面处的新化学键Ti-C的强度值和厚度值都比LAMP样品高，这些表明超声振动可以促进金属部件(Ti)和塑料部件(PET)之间的化学键Ti-C的生成。
<焊缝的失效载荷>
LAMP和UAL方法生成的焊接样品的载荷-位移曲线如图7所示。图8和9分别展示了试验后LAMP和UAL样品的失效形式。对于LAMP样品，所有断裂发生在金属-塑料界面处(图8)，而对于UAL焊接的样品，在母体塑料材料中发生断裂(图9)。这些结果表明UAL焊接的试样比LAMP焊接的试样具有更高的金属-塑料界面粘合强度。
关于激光功率对接头强度的影响，LAMP和UAL焊接的样品都观察到类似的趋势(图10)。开始时负载随着功率的增加而增加，并且在55W时达到最大值，然后在功率进一步增加时减小。在55W的激光功率参数下施加超声波时，抗拉强度提高了约38％(图10)。(UAL的平均失效负载＝1051N；LAMP的平均失效负载＝758N)
实例2
实例2使用低激光功率进行了更多的实验。该想法是为了避免例子1中提到的LAMP和UAL方法中因激光功率过高导致塑料过度受热发生降解形成气泡，并且证明在这样的条件下，本发明也优于常规LAMP方法(根据失效载荷)。UAL由激光光源(在该示例中是300W脉冲激光器)，超声振动装置(能够以28kHz的频率振动)和夹紧装置组成。实验中使用的焊接参数在表2中给出。
表2焊接参数
Figure BDA0001287777370000101
为了进行UAL焊接，将塑料片材(PET)放置在金属片材(Ti)之上。激光束透过石英板和塑料片，当其到达Ti表面时，激光热量被Ti吸收，结果，塑料片(PET)与金属片(Ti)接触的表面发生熔化，但不发生降解。激光功率保持在30W以内，以避免生成对焊接强度有害的聚合物分解物和气泡。在焊接过程中只是用一次的激光照射来实现焊接。搭接焊样品的焊缝长度约15mm。
<焊缝的材料和分析>
待焊接的材料是聚对苯二甲酸乙二醇酯(PET)片材和Ti片材(99.6％纯度)。PET片材高度透明，其化学式为(C10H8O4)n。待焊接的Ti和PET的尺寸均为60mm×20mm×1mm(长宽高)。所有样品的表面需要使用乙醇在超声清洗机中清洗10分钟。
使用XPS光谱仪来分析化学键，并使用万能材料试验机来评估焊缝的质量。为了进行焊接界面的XPS研究，通过机械方法分离PET/Ti焊件。为了分析焊接界面的化学键，使用Ar离子束溅射去除材料到不同深度。基于C1s线使用软件对焊接界面处形成的化学键进行的半定量分析。
<焊缝外观和失效载荷>
使用光学显微镜观察加载和不加载超声波振动所形成的焊接接头。图11展示出了LAMP(不加载超声)焊接样品和UAL(加载超声)焊接样品的典型焊缝外观和失效外观。所有样品均使用相同的激光参数(如表2所示)且激光功率保持在30W，在LAMP和UAL生产的焊缝中都没有观察到气泡(孔隙)。另外，发现如果使用高于30W的激光功率，则在LAMP生产的焊缝中会产生许多气泡(LAMP焊缝如实例1的图3)。
图12和图13展示出了在加载和不加载超声波振动的情况下形成焊缝的失效载荷情况。结果清楚地表明，当加载超声波振动时(UAL)，失效载荷显着增加，可以高达四倍(图13)。分析它们的断裂失效模式时，在加载和不加载超声波振动下形成的焊缝之间的失效载荷的差异是显而易见的。LAMP样品(不加载超声波振动)的失效发生在金属和塑料工件之间的界面处；而对于UAL样品(加载超声波振动)，断裂发生在母材塑料(图11)。
<XPS分析>
XPS(通过离子溅射来去除材料)作用于被焊接处的Ti表面。在60nm的深度，与实例1类似，对于两个样品，在大约281.7eV的位置观察到新峰，这在C1s谱线上被鉴定为Ti-C(图14和图15)。图14和15还表明，对于LAMP焊接样品，当深度达到600nm时，在281.7eV处的峰实际上已经消失。这表明包含Ti-C新化学键的界面厚度约为600nm。然而，对于UAL样品，这发生在1440nm的深度，即包含Ti-C新化学键的界面厚度约为1440nm。这表明UAL焊接样品界面处包含新化学键Ti-C的厚度明显大于LAMP焊接样品的厚度。
实例1和实例2的总结
在PET塑料与Ti金属的激光焊接中，将超声波振动施加到焊接区域，目的是改善焊接强度。这里研究了超声波振动对焊缝外观，焊接界面处的化学键和焊缝的拉伸失效载荷的影响。主要研究结果总结如下。
对于常规LAMP焊接方法，在某一激光功率之上，焊接区中气泡的形成是不可避免的，并且气泡的数量及体积在很大程度上取决于激光功率；在保持其他焊接条件不变的情况下，功率越高，气泡越多。另一方面，在本研究中除了使用高于55W(实例1)的高激光功率输入的条件之外，使用UAL焊接方法，可以消除由高分子材料降解生成的气泡。
当使用低激光功率时(30W)，无论加载超声波振动与否(即UAL和LAMP方法)，在所生成的焊缝中，都没有观察到气泡(实例2)。
超声波振动促进熔融PET和Ti金属之间的化学反应。XPS结果表明，UAL焊接样品在焊接界面处的Ti-C的强度值及厚度值都高于LAMP焊接样品。
比较LAMP和UAL焊接样品(均由低激光功率和高激光功率生成，即实施例1和2)的失效载荷，后者的失效载荷明显高于前者。
使用UAL方法生成的焊缝质量的提高是由于使用该方法消除(或大量减少)了焊缝中的气泡和/或形成强的化学键合界面。
UAL方法并不仅限于PET-Ti的焊接，可以应用于其它高分子材料(塑料)-金属/陶瓷焊接，并且相信能够获得类似于PET-Ti的焊接效果(即焊缝区域气泡大量减少或者完全消除，且化学键合强度提高)。
出于说明和描述的目的提供了本发明的前述描述。其并不旨在穷举或将本发明限制为所公开的具体形式。许多修改和变化对于本领域技术人员将是显而易见的。
选择和描述本实例是为了最好地解释本发明的原理及其实际应用，从而使得本领域的其他技术人员能够理解本发明的各种实例，并且应用于为特定使用而进行各种修改。意图是本发明的范围由所附权利要求及其等同物来限定。

Claims (11)

1.一种用于将高分子材料焊接到金属或陶瓷材料的激光焊接系统，包括：
激光系统，其用于发射至少一束激光束，该激光束用于照射通过以搭接的方式将高分子材料片放置在金属片或陶瓷片上而形成的工件的上表面，其中，高分子材料片的上表面形成所述工件的上表面，金属片或陶瓷片的下表面形成工件的下表面，在高分子材料片和金属片或陶瓷片之间形成焊缝界面，所述高分子材料片能被激光束透过；
超声振动装置，包括换能器和变幅杆，所述变幅杆允许将振动能量从所述换能器传递到所述工件并且能够以超声波频率和振动幅度振动，用于在激光焊接过程中，通过变幅杆的顶表面接触所述工件的下表面在工件施加超声振动，以经过所述金属片或陶瓷片施加压力于在焊缝界面处熔化的高分子材料，从而减少或消除在熔化的高分子材料中激光产生的气泡；以及
夹紧装置，包括夹紧气缸、可移动板和能被激光束透过的顶板，所述工件置于可移动板和顶板之间，所述可移动板在夹紧气缸的作用下和所述顶板向工件施加夹紧力来夹紧工件，所述夹紧装置夹持所述工件于所述激光系统和所述超声振动装置之间，使所述工件的上表面被激光束照射以及所述工件的下表面位于超声振动装置的变幅杆的顶表面上，以使所述变幅杆的顶表面接触在所述工件的下表面以施加超声振动；
其中，所述超声振动经过所述金属片或陶瓷片施加压力于焊接界面处熔化的高分子材料以减少或消除在焊接界面处熔化的高分子材料中激光产生的的气泡和增强高分子材料和金属或陶瓷材料之间的化学结合以形成强的化学键合界面，从而增强上述两种材料之间的焊接强度。
2.根据权利要求1所述的系统，其中，所述激光系统是脉冲激光器或连续波激光器。
3.根据权利要求1所述的系统，其中，所述变幅杆带有开槽。
4.一种使用权利要求1所述的系统以将高分子材料焊接到金属或陶瓷材料的方法，包括：
将所述高分子材料片放置在所述金属片或陶瓷片上以形成所述工件，其中，高分子材料片的上表面形成工件的上表面，金属片或陶瓷片的下表面形成工件的下表面，在高分子材料片和金属片或陶瓷片之间形成焊缝界面；
通过所述夹紧装置夹紧所述工件于所述激光系统和所述超声振动装置之间，使所述工件的上表面被激光束照射以及所述工件的下表面置于变幅杆的顶表面上；
所述激光束沿着焊接方向照射所述工件的上表面并透过所述顶板和高分子材料片以熔化在焊缝界面处高分子材料片的接触表面，在熔化的高分子材料中具有激光产生的气泡；以及
所述超声振动装置的变幅杆的顶表面沿着焊接方向接触所述工件的下表面以施加超声振动，以经过所述金属片或陶瓷片施加压力于在焊缝界面处熔化的高分子材料，从而减少或消除在熔化的高分子材料中激光产生的气泡。
5.根据权利要求4所述的方法，其中，所述高分子材料是塑料。
6.根据权利要求4所述的方法，其中，所述高分子材料是聚对苯二甲酸乙二醇酯(PET)，所述金属材料是钛(Ti)。
7.根据权利要求4所述的方法，其中，所述激光束具有在30W到75W范围内的平均功率。
8.根据权利要求4所述的方法，其中，所述激光束具有在15Hz至25Hz的范围内的脉冲频率。
9.根据权利要求4所述的方法，其中，所述激光束以6ms至10ms的范围内的脉冲持续时间工作。
10.根据权利要求4所述的方法，其中，所述超声振动的频率属于超声波范围。
11.根据权利要求4所述的方法，其中，所述振动幅度在2μm至6μm的范围内。
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