CN108526681B - 一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法 - Google Patents
一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法 Download PDFInfo
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Abstract
本发明公开了一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,利用搅拌摩擦搭接焊进行焊接,搅拌头转速及进给速度分别为1100rpm和50mm/min。焊接用有针搅拌头为平面圆锥型,搅拌针直径和长度分别为3.6mm和2.8mm。然后利用无针搅拌头进行搅拌摩擦加工,搅拌头进给速度为50mm/min,搅拌头转速范围为1200~2100rpm,搅拌头材料为碳化钨,轴肩直径12mm。本发明方法操作简单,可提高接头拉剪强度达到6倍多,具有实际意义。
Description
技术领域
本发明属于铸铁焊接技术领域,具体涉及一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法。
背景技术
铸铁在我国年产量已超过千万吨,是用途最广、产量最大的铸造合金。因其具有良好的耐磨性和减振性及低的缺口敏感性,且经特殊合金化后具有良好的耐热性和耐蚀性,年产量逐年递增,广泛用于机械制造业。球墨铸铁与低碳钢焊接常应用于机车车轮、汽车传动轴、法兰和某些设备承重梁组件的焊接。由于球墨铸铁含碳量较高,与低碳钢焊接时会增加熔融材料的含碳量,随后的冷却会使焊缝处生成马氏体组织,从而降低焊缝力学性能。
搅拌摩擦焊是一种新型固态焊接技术,可利用搅拌头的旋转和进给运动在金属板的搅拌区引起剧烈的塑性变形,焊接温度始终保持低于材料熔点,不会降低焊接件的质量,可用来焊接老化及硬化的铝合金等难焊材料。但是目前焊接技术存在有以下不足:.由于球墨铸铁含碳量较高,与低碳钢焊接时会增加熔融材料的含碳量,随后的冷却会使焊缝处生成马氏体组织,从而降低接头力学性能;球墨铸铁熔焊接过程中会出现裂纹、孔洞和力学性能恶化。
发明内容
针对上述存在的技术缺陷,本发明的目的在于提供一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,可以大幅提高接头处的拉剪强度。
为了达到上述技术效果,本发明具体通过以下技术方案实现:
一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,具体包括以下步骤:
1)分别对球墨铸铁和低碳钢进行前期处理是的规格形状相匹配,去除焊接面的氧化层,并用丙酮清洗吹干;
2)利用搅拌摩擦机进行搅拌摩擦搭接焊,将工件固定在工作台夹具上,调整主轴,启动主轴带动搅拌头旋转,随后控制搅拌头边旋转边插入被焊工件,轴肩最低端压入工件上表面0.15~0.25mm后停止插入;
3)预热5秒,开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,保持搅拌头向下的顶锻压力为16~18KN;
4)将被焊板料翻转,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,细化焊缝底部的材料晶粒。
所述的搅拌摩擦搭接焊的条件为:环境温度保持在25~30℃,湿度35%~45%。
所述的主轴调整具体为调整主轴倾斜角度为1~3°。
所述的步骤(2)中搅拌头转速范围为600~1100rpm,插入被焊工件的速度为0.04mm/s。
所述的主轴横向进给速度为40~60mm/min。
所述的搅拌摩擦搭接焊采用的搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为11~13mm。
所述的步骤(4)中无针搅拌头进给速度为40~60mm/min,搅拌头转速范围为1200~2100rpm,轴肩直径为11~13mm。
本发明的有益效果为:
本发明技术方法可以避免球墨铸铁与低碳钢焊接时由于冷却造成焊缝处生成马氏体组织,从而提高接头力学性能,经试验证明,随无针搅拌头转速提高,试样拉剪断裂载荷呈现增大趋势,当无针搅拌头转速和进给速度分别为2100rpm和50mm/min时,试样拉剪断裂载荷最大,达到6400N,为原接头的6倍多。
具体实施方式
下面将结合本发明具体的实施例,对本发明技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明实施例中采用奥氏体基球墨铸铁和08F低碳钢作为母材,其化学成分如表1所示,利用搅拌摩擦搭接焊进行焊接,搅拌头转速及进给速度分别为1100rpm和50mm/min。焊接用有针搅拌头为平面圆锥型,搅拌针直径和长度分别为3.6mm和2.8mm。然后利用无针搅拌头进行搅拌摩擦加工,搅拌头进给速度为50mm/min,搅拌头转速范围为1200~2100rpm,搅拌头材料为碳化钨,轴肩直径12mm。
表1母材化学成分表
实施例1
利用搅拌摩擦搭接焊,对奥氏体基球墨铸铁和08F低碳钢进行焊接,先将厚1.2mm的08F钢加工成95mm×40mm,将厚3mm的球墨铸铁加工成95mm×40mm,然后去除焊接面的氧化层、用丙酮清洗并吹干,利用搅拌摩擦机进行搅拌摩擦搭接焊,环境温度保持在25~30℃,湿度35%~45%。焊接所用搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为12mm,搅拌针直径和长度分别为3.6mm和2.8mm。首先将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速范围为1100rpm,随后控制搅拌头边旋转边插入被焊工件,插入速度为0.04mm/s,轴肩最低端压入工件上表面0.2mm后停止插入;主轴插入被焊工件后预热5秒,随后开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,进给速度为40~60mm/min,保持搅拌头向下的顶锻压力为16~18KN。对搭接焊接头进行拉剪实验,得到拉剪最大载荷为980N。
实施例2
利用搅拌摩擦搭接焊,对奥氏体基球墨铸铁和08F低碳钢进行焊接,先将厚1.2mm的08F钢加工成95mm×40mm,将厚3mm的球墨铸铁加工成95mm×40mm,然后去除焊接面的氧化层、用丙酮清洗并吹干,利用搅拌摩擦机进行搅拌摩擦搭接焊,环境温度保持在25~30℃,湿度35%~45%。焊接所用搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为12mm,搅拌针直径和长度分别为3.6mm和2.8mm。首先将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速范围为1100rpm,随后控制搅拌头边旋转边插入被焊工件,插入速度为0.04mm/s,轴肩最低端压入工件上表面0.2mm后停止插入;主轴插入被焊工件后预热5秒,随后开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,进给速度为40~60mm/min,保持搅拌头向下的顶锻压力为16~18KN。将被焊板料翻过来,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,从而细化焊缝底部的材料晶粒,搅拌头进给速度为40~60mm/min,搅拌头转速范围为1200rpm,搅拌头材料为碳化钨合金(Co含量为13wt%),轴肩直径10~12mm。对搭接焊接头进行拉剪实验,得到拉剪最大载荷为5600N。
实施例3
利用搅拌摩擦搭接焊,对奥氏体基球墨铸铁和08F低碳钢进行焊接,先将厚1.2mm的08F钢加工成95mm×40mm,将厚3mm的球墨铸铁加工成95mm×40mm,然后去除焊接面的氧化层、用丙酮清洗并吹干,利用搅拌摩擦机进行搅拌摩擦搭接焊,环境温度保持在25~30℃,湿度35%~45%。焊接所用搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为12mm,搅拌针直径和长度分别为3.6mm和2.8mm。首先将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速范围为1100rpm,随后控制搅拌头边旋转边插入被焊工件,插入速度为0.04mm/s,轴肩最低端压入工件上表面0.2mm后停止插入;主轴插入被焊工件后预热5秒,随后开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,进给速度为40~60mm/min,保持搅拌头向下的顶锻压力为16~18KN。将被焊板料翻过来,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,从而细化焊缝底部的材料晶粒,搅拌头进给速度为40~60mm/min,搅拌头转速范围为1500rpm,搅拌头材料为碳化钨合金(Co含量为13wt%),轴肩直径10~12mm。对搭接焊接头进行拉剪实验,得到拉剪最大载荷为6000N。
实施例4
利用搅拌摩擦搭接焊,对奥氏体基球墨铸铁和08F低碳钢进行焊接,先将厚1.2mm的08F钢加工成95mm×40mm,将厚3mm的球墨铸铁加工成95mm×40mm,然后去除焊接面的氧化层、用丙酮清洗并吹干,利用搅拌摩擦机进行搅拌摩擦搭接焊,环境温度保持在25~30℃,湿度35%~45%。焊接所用搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为12mm,搅拌针直径和长度分别为3.6mm和2.8mm。首先将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速范围为1100rpm,随后控制搅拌头边旋转边插入被焊工件,插入速度为0.04mm/s,轴肩最低端压入工件上表面0.2mm后停止插入;主轴插入被焊工件后预热5秒,随后开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,进给速度为40~60mm/min,保持搅拌头向下的顶锻压力为16~18KN。将被焊板料翻过来,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,从而细化焊缝底部的材料晶粒,搅拌头进给速度为40~60mm/min,搅拌头转速范围为1800rpm,搅拌头材料为碳化钨合金(Co含量为13wt%),轴肩直径10~12mm。对搭接焊接头进行拉剪实验,得到拉剪最大载荷为6100N。
实施例5
利用搅拌摩擦搭接焊,对奥氏体基球墨铸铁和08F低碳钢进行焊接,先将厚1.2mm的08F钢加工成95mm×40mm,将厚3mm的球墨铸铁加工成95mm×40mm,然后去除焊接面的氧化层、用丙酮清洗并吹干,利用搅拌摩擦机进行搅拌摩擦搭接焊,环境温度保持在25~30℃,湿度35%~45%。焊接所用搅拌头为平面圆锥型,材料为碳化钨合金(Co含量为13wt%),轴肩直径为12mm,搅拌针直径和长度分别为3.6mm和2.8mm。首先将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速范围为1100rpm,随后控制搅拌头边旋转边插入被焊工件,插入速度为0.04mm/s,轴肩最低端压入工件上表面0.2mm后停止插入;主轴插入被焊工件后预热5秒,随后开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,进给速度为40~60mm/min,保持搅拌头向下的顶锻压力为16~18KN。将被焊板料翻过来,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,从而细化焊缝底部的材料晶粒,搅拌头进给速度为40~60mm/min,搅拌头转速范围为2100rpm,搅拌头材料为碳化钨合金(Co含量为13wt%),轴肩直径10~12mm。对搭接焊接头进行拉剪实验,得到拉剪最大载荷为6400N。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (4)
1.一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,其特征在于,包括以下步骤:
1)分别对球墨铸铁和低碳钢进行前期处理使得规格形状相匹配,去除焊接面的氧化层,并用丙酮清洗吹干;
2)利用搅拌摩擦机进行搅拌摩擦搭接焊,将工件固定在工作台夹具上,调整主轴倾斜角度为1~3°,启动主轴带动搅拌头旋转,搅拌头转速为1100rpm,随后控制搅拌头边旋转边插入被焊工件,轴肩最低端压入工件上表面0.15~0.25mm后停止插入;搅拌摩擦搭接焊的条件为:环境温度保持在25~30℃,湿度35%~45%;
3)预热5秒,开启主轴振动开关,振幅20μm,振动频率22~26KHz,启动主轴横向进给,保持搅拌头向下的顶锻压力为16~18KN;
4)将被焊板料翻转,使原焊缝底部朝上,固定在夹具上,利用无针搅拌头沿着原焊缝进行搅拌摩擦加工,细化焊缝底部的材料晶粒;所述的无针搅拌头进给速度为40~60mm/min,搅拌头转速范围为1200~2100rpm。
2.根据权利要求1所述的一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,其特征在于,所述的步骤2)中插入被焊工件的速度为0.04mm/s。
3.根据权利要求1所述的一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,其特征在于,所述的主轴横向进给速度为40~60mm/min。
4.根据权利要求1所述的一种提高球墨铸铁与低碳钢搭接接头拉剪强度的方法,其特征在于,所述的搅拌摩擦搭接焊采用的搅拌头为平面圆锥型,材料为碳化钨合金,轴肩直径为11~13mm。
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