CN109382578B - Friction welding quality detection and evaluation method - Google Patents
Friction welding quality detection and evaluation method Download PDFInfo
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- CN109382578B CN109382578B CN201710686475.4A CN201710686475A CN109382578B CN 109382578 B CN109382578 B CN 109382578B CN 201710686475 A CN201710686475 A CN 201710686475A CN 109382578 B CN109382578 B CN 109382578B
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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
- 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
Abstract
The invention discloses a method for detecting and evaluating the quality of friction welding, which solves the problem of evaluating the quality of a friction welding joint, can realize the evaluation of the quality of the friction welding joint according to the size and the bending angle of a flash of the friction welding joint, has more visual flash appearance and simpler and more convenient detection mode, and can quickly and accurately evaluate the quality of the welding joint by the detection of the visual representation of the flash appearance. The technical scheme is as follows: determining the characteristic parameter range of the flash which represents the qualified quality of the welding joint; carrying out welding operation, and collecting characteristic parameters of the welded sample flash; and based on the characteristic parameter range, evaluating the quality of the welding joint according to the characteristic parameters.
Description
Technical Field
The invention belongs to the technical field of welding, and relates to a friction welding quality detection and evaluation method.
Background
Friction welding is a typical solid phase joining technique. Because the welding process has low temperature and no metal melting phenomenon, the joint has the advantages of compact structure, low stress, high strength and low energy consumption under the action of upsetting pressure. The method is widely applied to the industrial fields of aviation, aerospace, automobiles, energy sources and the like.
In the friction welding process, the initial friction surface metal possibly containing impurities such as an oxide film and the like is extruded out of a friction interface under the action of friction pressure and jacking pressure, so that the friction joint is formed by clean metal, and the method is the basis for avoiding the formation of welding defects such as 'grey spots', unwelded welding and the like and ensuring qualified welding quality. However, the influence mechanism of welding process parameters such as friction pressure, upset forging pressure, rotating speed and the like on the quality of the friction welding joint is complex, no suitable model is available at present for determining the welding process parameter range of qualified welding quality, the welding quality is judged according to a mechanical property test result, and direct detection and analysis on the quality of the friction welding joint are lacked.
In the processes of rotating friction welding and non-rotating friction welding, the flashes are taken as typical macro-topography of a friction welding joint (including the size and the shape of the flashes), and can be used for representing the extrusion condition of plastic metal at a friction interface in the joint; the formation of a joint from clean metal with a fully extruded oxide film at the friction interface is a basic condition for obtaining a satisfactory friction weld joint. Thus, the friction weld joint flash can be used to characterize the quality of the friction weld joint. For the relation among welding process parameters, plastic material flow, flash appearance and welding quality, from the invention of the rotary friction welding technology to the present, a great deal of research work is carried out by research workers, and a basis is provided for judging the performance of a welding joint, optimizing the welding process and the like by observing the flash appearance.
For example, when the rotating speed is too low or the upsetting pressure is too small, the temperature of the friction interface material is low, the plasticity is poor, and the plastic flow speed is low, so that the original oxides on the friction interface are difficult to extrude out and remain in the joint to form defects of slag inclusion, gray specks, unwelded joint and the like under the low upsetting pressure; under such conditions, the flash formed is of a smaller size due to less plastic metal being extruded during upset forging. When the rotating speed is too high or the upsetting pressure is too large, the friction interface material is high in temperature, good in plasticity and good in material fluidity, and under the large upsetting pressure, a large amount of friction interface plastic metal is extruded to form a large-size flash; at this time, too much high-temperature material is extruded, so that the rotation shortening is too large, and the center of the welding joint cannot form effective metallurgical bonding to form a non-welding defect. Therefore, when the size of the flash and the bending angle meet the requirements of a certain range, the materials on the initial friction interface with the oxide are all extruded, so that a clean friction interface is exposed, the basic conditions for forming a qualified joint are met, and the quality of the welded joint meets the process standard.
However, in the conventional method for evaluating the quality of the spin friction welding joint, corresponding research on establishing the relationship between the quality of the spin friction welding joint and the appearance of the flash to form the method for evaluating the welding quality is lacked. In addition, in the prior art evaluation method, the flash morphology is only used as an empirical auxiliary reference for macroscopic observation, relatively uniform standards and evaluation mechanisms are not formed, and the improvement is urgently needed.
In summary, the prior art lacks an effective solution to the problem of joint quality assessment during friction welding.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for detecting and evaluating the quality of friction welding based on flash detection, which can quickly and accurately evaluate the quality of a rotary friction welding head by detecting the size and the shape of the flash.
A friction welding quality detection and evaluation method comprises the following steps:
(1) determining the characteristic parameter range of the flash which represents the qualified quality of the welding joint;
determining a lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and an upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded, thereby determining the range of the flash characteristic parameters for forming the welding joint with qualified quality;
(2) carrying out welding operation, and collecting characteristic parameters of the welded sample flash;
(3) and (3) evaluating the quality of the welding joint according to the characteristic parameters in the step (2) based on the characteristic parameter range in the step (1).
Further, the step (1) comprises the following steps:
aiming at welding conditions: the welding method, the material and the sample specification are determined, test process parameters are determined, a plurality of samples are subjected to test welding for a plurality of times respectively, after test results are counted, the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded under different welding conditions and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined respectively, and therefore the flash characteristic parameter range of the welding joint with qualified quality is determined.
Further preferably, the determining step of the lower critical characteristic parameter and the upper critical characteristic parameter comprises:
marking the flow behavior of a friction interface material in the friction welding process by using tracer particles, and determining a lower critical characteristic parameter of a flash when a material on an initial friction interface with an oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal of the friction interface is completely extruded according to the motion trail of the tracer particles.
Further preferably, the determining step of the lower critical characteristic parameter and the upper critical characteristic parameter comprises:
the flow behavior of the friction interface material in the friction welding process is numerically simulated, and the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal of the friction interface is completely extruded are determined through calculation.
Further, when the welding condition is a welding mode, the specific steps of the step (1) are as follows:
determining test process parameters aiming at different welding modes of the rotary friction welding, performing a plurality of times of test welding on a plurality of samples, counting test results, and determining a lower critical characteristic parameter of a flash when a material on an initial friction interface with an oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal on the friction interface is completely extruded, thereby determining a flash characteristic parameter range of a joint with qualified quality; preferably, marking the flowing behavior of the friction interface material in the friction welding process by using tracer particles, and determining the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal of the friction interface is completely extruded according to the movement track of the tracer particles, so as to determine the range of the flash characteristic parameters for forming the qualified joint; preferably, the flow behavior of the friction interface material in the process of rotating friction welding is simulated by numerical values, and the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined by calculation, so that the flash characteristic parameter range of the qualified joint is determined.
Further, when the welding condition is material, the specific steps of the step (1) are as follows:
determining test process parameters aiming at different materials, carrying out multiple test welding on a plurality of samples, counting test results, and then determining a lower critical characteristic parameter of a flash when the material on an initial friction interface with oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal on the friction interface is completely extruded, thereby determining the range of the flash characteristic parameters for forming the qualified quality joint; preferably, marking the flowing behavior of the friction interface material in the friction welding process by using tracer particles, and determining the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal of the friction interface is completely extruded according to the movement track of the tracer particles, so as to determine the range of the flash characteristic parameters for forming the qualified joint; preferably, the flow behavior of the friction interface material in the process of rotating friction welding is simulated by numerical values, and the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined by calculation, so that the flash characteristic parameter range of the qualified joint is determined.
Further, when the welding condition is a sample specification, the specific steps of the step (1) are as follows:
determining test process parameters aiming at different sample specifications, carrying out multiple test welding on a plurality of samples, and after counting test results, determining a lower critical characteristic parameter of a flash when a material on an initial friction interface with an oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal on the friction interface is completely extruded, thereby determining a flash characteristic parameter range for forming a qualified quality joint; preferably, marking the flowing behavior of the friction interface material in the friction welding process by using tracer particles, and determining the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal of the friction interface is completely extruded according to the movement track of the tracer particles, so as to determine the range of the flash characteristic parameters for forming the qualified joint; preferably, the flow behavior of the friction interface material in the process of rotating friction welding is simulated by numerical values, and the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined by calculation, so that the flash characteristic parameter range of the qualified joint is determined.
Further, the characteristic parameters of the flash include the size of the flash and the bending angle of the flash.
Further, the step of collecting characteristic parameters of the flash in the step (2) is as follows:
after welding, the size of the welded sample flash is measured by a cotton thread method, and the bending angle of the welded sample flash is measured by a protractor.
Preferably, the step of collecting characteristic parameters of the flash in the step (2) is:
in the friction welding process, a vision sensor is adopted to collect images of sample flashes in real time, and the size and the bending angle of the flashes are obtained in real time through an image processing technology.
Further, the vision sensor includes, but is not limited to, an industrial video camera, a high speed video camera, a linear scanning laser, a camera.
Further, the specific steps of the step (3) are as follows:
comparing whether the characteristic parameters of the flashes in the step (2) are in the range of the characteristic parameters of the flashes forming the welding joint with qualified quality, and if so, evaluating the quality of the welding joint of the sample in the step (2) as qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
In order to overcome the defects of the prior art, the invention also provides another friction welding quality detection and evaluation method, which comprises the following steps:
(1) determining an image of a flash representing qualified quality of a welded joint;
performing trial welding on the sample to obtain an image of a flash corresponding to the qualified welded joint;
(2) carrying out welding operation, and acquiring an image of sample flash in the friction welding process in real time;
(3) processing the image of the sample flash in real time by using an image processor, matching the image with the image in the step (1), and if the matching rate is more than 75%, evaluating that the quality of the welding joint of the sample in the step (2) is qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
Compared with the prior art, the invention has the beneficial effects that:
the method can realize the evaluation of the quality of the rotating friction welding joint according to the characteristic parameters of the size, the bending angle and the like of the flash shape of the friction welding joint, the flash shape is more visual, the detection mode is simpler and more convenient, and the quality of the welding joint can be quickly and accurately evaluated through the detection of the visual representation of the flash shape.
The method can effectively overcome the defects of high development cost and long development period in the traditional friction welding process design and optimization mainly adopted trial and error method and the research design method combining numerical simulation with a small amount of tests.
After the test welding of the sample is carried out, the lower critical characteristic parameter of the flash morphology when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash morphology when the plastic metal on the friction interface is completely extruded can be determined, and the range of the flash characteristic parameter for forming the qualified joint can be further determined, so that the flash characteristic parameter range for obtaining the qualified joint can be directly compared with the range of the flash characteristic parameter for obtaining the qualified joint in subsequent welding process operation, and whether the welded joint is qualified or not can be simply, quickly and accurately obtained.
The method can adopt an image acquisition mode to acquire the flash image in real time in the welding process, and extract the characteristic parameters of the flash through the image processor to be matched with the flash image obtained in the trial welding.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application.
FIG. 1a is a flash topography plot obtained at 5s friction time;
FIG. 1b is a plot of the profile of the flash as obtained over a rubbing time of 7 s;
FIG. 1c is a plot of the profile of the flash as obtained over a 10s rubbing time;
FIG. 2 is a schematic diagram of a measurement standard of the flash topography;
FIG. 3 is a profile of the flash obtained in example 1;
FIG. 4 is a profile of the flash obtained in example 2.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
As described in the background of the invention, the quality of a spin friction welding joint is evaluated in the prior art, and in order to solve the above technical problems, the present application proposes a friction welding quality detection and evaluation method, which can be applied to non-spin friction welding and spin friction welding.
In an exemplary embodiment of the present application, a method for detecting and evaluating the quality of friction welding is provided, which performs process evaluation on the quality of a welded joint by detecting characteristic parameters such as the size of a flash and a bending angle. The detection of the appearance of the flash is used for achieving the purpose of rapidly and accurately judging the quality of the welding joint.
Specifically, the steps of the invention are as follows:
(1) determining a range of characteristic parameters of the flash, which characterize the qualified quality of the welding joint;
aiming at welding requirements of different non-rotary friction welding modes and rotary friction welding modes (including continuous drive rotary friction welding and inertia rotary friction welding which also include axial friction welding and radial friction welding), different materials and sample specifications, multiple times of trial welding are carried out on a plurality of samples, after test results are counted, lower critical characteristic parameters of burrs when all materials on an initial friction interface with oxides are extruded and upper critical characteristic parameters of the burrs when plastic metal on the friction interface is completely extruded are determined, and therefore the range of the burr characteristic parameters for forming the qualified quality joint is determined;
marking the flowing behavior of a friction interface material in the friction welding process by using tracer particles, and determining a lower critical characteristic parameter of a flash when a material on an initial friction interface with an oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal of the friction interface is completely extruded according to the motion trail of the tracer particles, so as to determine the range of the flash characteristic parameters for forming a qualified joint;
the method is characterized in that the flowing behavior of a friction interface material in the rotating friction welding process is simulated by numerical values, the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined by calculation, and therefore the flash characteristic parameter range of the formed qualified joint is determined.
And (3) taking the size and the bending angle change of the flash as standard indexes of the appearance of the flash, representing the range of the characteristic parameters of the flash with qualified joint quality, and determining the necessary conditions of qualified quality of the welded joint.
(2) Acquiring characteristic parameters of the flash;
and carrying out welding process operation according to related parameter requirements, and obtaining the flash appearance of the welding joint.
The flash morphology can be obtained in the following two ways:
1) the shape of the welding joint flash can be measured by a cotton thread method and a protractor, and the size and the bending angle of the flash are obtained;
preferably: 2) the flash morphology is collected through a vision sensor (namely the flash morphology of the welded joint can be shot according to a certain proportion through a camera), and the flash characteristic parameters are extracted by utilizing an image processing technology, for example: the flash size and the bending angle are obtained by means of a computer image recognition tool (one way that can be taken is to introduce the picture into a Photoshop for measurement).
Visual sensors include, but are not limited to, industrial cameras, high speed cameras, and linear scanning laser, camera, etc. detection instruments.
(3) Matching the shapes of the flashes in the step (2) and the step (1) to obtain a process evaluation result;
and (3) comparing the flash characteristic parameters obtained in the step (2) with the range of the flash characteristic parameters representing qualified joint quality, and giving an evaluation result.
Comparing the characteristic parameters of the flash extracted in the step (2) with the critical characteristic parameters in the step (1), and if the extracted characteristic parameters of the flash are within the range of the characteristic parameters of the flash which is obtained in the step (1) and forms the welding joint with qualified quality, evaluating the quality of the welding joint of the sample in the step (2) to be qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
In another exemplary embodiment of the present application, a method for detecting and evaluating the quality of a spin friction weld is provided, which includes the steps of:
(1) determining an image of a flash representing qualified quality of a welded joint;
performing trial welding on the sample to obtain an image of a flash corresponding to the qualified welded joint;
(2) carrying out welding operation, and collecting an image of the welded sample flash;
(3) processing the image of the sample flash in real time by using an image processor, matching the image with the image in the step (1), and if the matching rate is more than 75%, evaluating that the quality of the welding joint of the sample in the step (2) is qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
In order to make the technical solutions of the present application more clearly understood by those skilled in the art, the technical solutions of the present application will be described in detail below with reference to specific embodiments.
Taking a GH4196 high-temperature alloy bar with the specification of a continuous drive friction welding sample of 10.5mm as an example, determining the characteristic parameter range of the flash which represents the qualified quality of a welding joint. And selecting test parameters of 2200rpm of rotation speed, 100MPa of friction pressure, 200MPa of upsetting pressure, 10s of upsetting time and 5s, 7s and 10s of friction time according to the numerical simulation result and empirical parameters to perform a welding test to obtain the shapes of the flash, wherein the shapes are respectively shown in figures 1a, 1b and 1 c. According to the measurement standards shown in FIG. 2, the sizes of the burrs of the formed welded joint are determined to be 1.7mm-3.2mm when the quality of the welded joint is qualified, the bending angles are 75.7-89.2 degrees, and the like, so that the sizes are defined as the characteristic parameter ranges of the burrs of the GH4196 high-temperature alloy bar with qualified friction welding quality of 10.5 mm.
And operating as an example, and obtaining the range of the characteristic parameters of the flash, which are qualified for characterizing the quality of the joint under the requirement of each conventional welding in the same way.
(2) Acquiring characteristic parameters of sample flashes;
and carrying out welding process operation according to related parameter requirements, and obtaining the flash appearance of the welding joint.
1) The shape of the welding joint flash can be measured by a cotton thread method and a protractor, and the size and the bending angle of the flash are obtained; preferably: 2) the flash morphology is collected through a vision sensor (namely the flash morphology of the welded joint can be shot according to a certain proportion through a camera), and the flash characteristic parameters are extracted through an image processing technology.
Example 1:
setting parameters of a rotating speed of 2200rpm, a friction pressure of 80MPa, an upsetting pressure of 200MPa, upsetting time of 12s and friction time of 5s aiming at a GH4196 high-temperature alloy bar with a diameter of 10.5mm in a continuously-driven friction welding sample specification, and obtaining the shape of a welding joint flash as shown in figure 3, wherein the extracted characteristic parameters are as follows: the flash size was 2.0mm and the bend angle was 77.3 °.
Example 2:
setting parameters of a rotating speed of 2200rpm, a friction pressure of 120MPa, an upsetting pressure of 240MPa, upsetting time of 10s and friction time of 6s aiming at a GH4196 high-temperature alloy bar with a diameter of 10.5mm of a continuously-driven friction welding sample specification, and obtaining the welding joint flash appearance as shown in figure 4, wherein the extracted characteristic parameters are as follows: the flash size was 3.8mm and the bend angle was 73.1 °.
(3) Evaluating the quality of the rotary friction welding according to the characteristic parameters of the flash;
extracting characteristic parameters of the flashes, comparing the characteristic parameters with the range of the flash characteristic parameters of qualified quality of the formed joint in the step (1), and if the extracted characteristic parameters of the flashes are located in the range of the flash characteristic parameters of qualified quality of the formed joint, evaluating the quality of the welded joint of the sample in the step (2) to be qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
In example 1, the obtained flash has a feature size of 1.7mm < 2.0mm < 3.2mm, a bending angle of 75.7 DEG < 77.3 DEG < 89.2 DEG, and the quality of the welded joint is considered to be excellent within the range of characteristic parameters.
In example 2, the obtained flash has a shape and size of 3.8mm & gt 3.2mm, a bending angle of 73.1 degrees & lt 77.3 degrees, and the quality of the welded joint is not qualified if the sizes are outside the range of characteristic parameters.
The above evaluation process can also be realized by image acquisition and matching:
acquiring an image of a flash of a friction welding sample under the condition that the welding quality is qualified by an industrial camera and the like in the step (1);
in the step (2), an image of a welding joint flash in the welding operation is obtained through an industrial camera and the like;
and (3) matching the image of the welded sample flash with the image in the step (1) by adopting an image processor, if the obtained flash morphology image can be matched with the flash morphology image in the step (1) by an SIFT algorithm in OpenCV, if the matching rate is more than 75%, the quality of the welded joint is qualified, otherwise, the quality of the welded joint is unqualified.
The images obtained in the embodiment 1 are matched in OpenCV through SIFT algorithm, and the matching rate of the shapes of the burrs is 84%, so that the quality of the welded joints is considered to be excellent.
And (3) matching the image obtained in the embodiment 2 in OpenCV through an SIFT algorithm, wherein the matching rate of the shapes of the burrs is 67%, and determining that the quality of the welded joint is unqualified.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (9)
1. A friction welding quality detection and evaluation method is characterized by comprising the following steps:
(1) determining the characteristic parameter range of the flash which represents the qualified quality of the welding joint;
determining a lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and an upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded, thereby determining the range of the flash characteristic parameters for forming the welding joint with qualified quality; determining an upper critical characteristic parameter and a lower critical characteristic parameter of the flash by adopting a tracer particle mark or a numerical simulation method;
(2) carrying out welding operation, and collecting characteristic parameters of the welded sample flash;
(3) and (3) evaluating the quality of the welding joint according to the characteristic parameters in the step (2) based on the characteristic parameter range in the step (1).
2. The assessment method according to claim 1, wherein said step (1) comprises the steps of:
aiming at welding conditions: the welding method, the material and the sample specification are determined, test process parameters are determined, a plurality of samples are subjected to test welding for a plurality of times respectively, after test results are counted, the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded under different welding conditions and the upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded are determined respectively, and therefore the flash characteristic parameter range of the welding joint with qualified quality is determined.
3. An assessment method according to claim 2, characterized in that the determination of the lower critical characteristic parameter and the upper critical characteristic parameter comprises the steps of:
marking the flow behavior of a friction interface material in the friction welding process by using tracer particles, and determining a lower critical characteristic parameter of a flash when a material on an initial friction interface with an oxide is completely extruded and an upper critical characteristic parameter of the flash when plastic metal of the friction interface is completely extruded according to the motion trail of the tracer particles.
4. An assessment method according to claim 2, characterized in that the determination of the lower critical characteristic parameter and the upper critical characteristic parameter comprises the steps of:
the flow behavior of the friction interface material in the friction welding process is numerically simulated, and the lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and the upper critical characteristic parameter of the flash when the plastic metal of the friction interface is completely extruded are determined through calculation.
5. The assessment method according to claim 1, wherein the characteristic parameters of said flash comprise the dimensions of the flash and the bending angle of the flash.
6. The assessment method according to claim 1, wherein the step of collecting the characteristic parameters of the flash in the step (2) comprises the steps of:
after welding, the size of the welded sample flash is measured by a cotton thread method, and the bending angle of the welded sample flash is measured by a protractor.
7. The assessment method according to claim 1, wherein the specific steps of said step (3) are:
comparing whether the characteristic parameters of the flashes in the step (2) are in the range of the characteristic parameters of the flashes forming the welding joint with qualified quality, and if so, evaluating the quality of the welding joint of the sample in the step (2) as qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
8. A friction welding quality detection and evaluation method is characterized by comprising the following steps:
(1) determining an image of a flash representing qualified quality of a welded joint;
determining the characteristic parameter range of the flash which represents the qualified quality of the welding joint;
determining a lower critical characteristic parameter of the flash when the material on the initial friction interface with the oxide is completely extruded and an upper critical characteristic parameter of the flash when the plastic metal on the friction interface is completely extruded, thereby determining the range of the flash characteristic parameters for forming the welding joint with qualified quality; determining an upper critical characteristic parameter and a lower critical characteristic parameter of the flash by adopting a tracer particle mark or a numerical simulation method;
the method for acquiring the characteristic parameters of the flash comprises the following steps: in the friction welding process, a visual sensor is adopted to collect images of sample flashes in real time, and the size and the bending angle of the flashes are obtained in real time through an image processing technology;
performing trial welding on the sample to obtain an image of a flash corresponding to the qualified welded joint;
(2) carrying out welding operation, and acquiring an image of sample flash in the friction welding process in real time;
(3) processing the image of the sample flash in real time by using an image processor, matching the image with the image in the step (1), and if the matching rate is more than 75%, evaluating that the quality of the welding joint of the sample in the step (2) is qualified; and (3) otherwise, evaluating the quality of the welding joint of the sample in the step (2) to be unqualified.
9. The assessment method of claim 8 wherein said visual sensor includes, but is not limited to, an industrial camera, a high speed camera, a linear scanning laser, a camera.
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