CN109967858B - 一种适用于金属与聚合物之间的搅拌摩擦焊接方法 - Google Patents

一种适用于金属与聚合物之间的搅拌摩擦焊接方法 Download PDF

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CN109967858B
CN109967858B CN201910225037.7A CN201910225037A CN109967858B CN 109967858 B CN109967858 B CN 109967858B CN 201910225037 A CN201910225037 A CN 201910225037A CN 109967858 B CN109967858 B CN 109967858B
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shaft shoulder
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follow
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CN109967858A (zh
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黄永宪
孟祥晨
谢聿铭
李峻臣
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Harbin Institute of Technology
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Abstract

本发明提出了一种适用于金属与聚合物之间的搅拌摩擦焊接方法，属于搅拌摩擦焊领域，特别是涉及一种适用于金属与聚合物之间的搅拌摩擦焊接方法。解决了聚合物与金属搅拌摩擦焊接头表面成形差和力学性能低等问题。它包括焊前清理、待焊板材装夹定位、随动轴肩的安装、加热随动轴肩和搅拌摩擦焊接等步骤。它主要用于金属与聚合物之间的搅拌摩擦焊接。

Description

一种适用于金属与聚合物之间的搅拌摩擦焊接方法
技术领域
本发明属于搅拌摩擦焊领域，特别是涉及一种适用于金属与聚合物之间的搅拌摩擦焊接方法。
背景技术
在国家节能减排和建设制造强国的大环境下，轻量化提高能效比已成为交通领域的共同目标。构件的轻量化设计是提高性能、节能降耗、减少环境污染的有效途径之一。目前，能够满足结构使役性能和轻量化设计的重要途径为材料本体性能提高和材料的优化配置。通过聚合物/金属复合结构的设计可满足气体排放要求。可见，聚合物/金属复合结构能够满足结构性能和轻量化设计的双重技术指标，但其涉及的焊接技术作为轻量化设计中关键问题仍未得到有效的解决。
搅拌摩擦焊作为一种固相连接技术，涉及温度、力学、冶金及其相互作用，具有焊接温度低、塑性变形剧烈、接头质量高、绿色无污染等特点，并且可有效避免由熔化—凝固过程所引起的裂纹、气孔等缺陷，基本不受材料物理化学性质及晶体结构等因素的影响，对克服异种材料性能差异带来的焊接困难具有较大优势。但是在金属/聚合物复合材料搅拌摩擦焊接时，易出现焊缝成形困难和接头强度低等问题。
发明内容
本发明为了解决现有技术中的问题，提出一种适用于金属与聚合物之间的搅拌摩擦焊接方法。
为实现上述目的，本发明采用以下技术方案：一种适用于金属与聚合物之间的搅拌摩擦焊接方法，它包括以下步骤：
步骤一：进行焊前清理，使用有机溶剂或清洗剂对待焊板材进行擦拭，去除表面杂物，所述待焊板材为聚合物材料板材和金属材料板材；
步骤二：使用工装夹具对待焊板材进行装夹，使待焊板材对接面相互靠近，采用聚合物材料板材位于上层，金属材料板材位于下层的配置原则；
步骤三：采用机械连接的方式，将随动轴肩安装在搅拌摩擦焊机上，所述随动轴肩嵌套在搅拌头外侧，所述随动轴肩底面与搅拌头轴肩平齐，所述随动轴肩内部设置有加热装置，所述随动轴肩跟随搅拌头做同步平面运动；
步骤四：开启加热装置对随动轴肩进行加热，驱动搅拌头旋转使搅拌针下扎至待焊板材中，直至随动轴肩底面与聚合物材料板材上表面紧密接触时停止下扎；
步骤五：随动轴肩对待焊板材充分预热后，驱动搅拌头以设定焊接速度向前运动进行焊接，随动轴肩保持加热状态并跟随搅拌头向前运动对待焊板材进行预热，当达到焊接距离后，搅拌头向上抬起，关闭加热装置，完成焊接过程。
更进一步的，所述有机溶剂为酒精或丙酮。
更进一步的，所述随动轴肩与加热装置为一体式结构或分体式机构。
更进一步的，所述随动轴肩的材质为钢、铜合金或钨铼合金。
更进一步的，所述加热装置的加热方式为热棒、热风或火焰辅助加热。
更进一步的，所述随动轴肩形状为平面形结构或曲面形结构。
更进一步的，所述加热装置对随动轴肩的加热温度为聚合物材料板材熔点的10-100％。
更进一步的，所述搅拌头的旋转速度为200-1000rpm，焊接速度为5-1000mm/min，所述搅拌头轴肩倾角为0-5度。
与现有技术相比，本发明的有益效果是：
1.本发明通过随动轴肩有效对位于上层的聚合物材料板材进行充分预热，避免了聚合物低热导率易导致缺陷的问题，有效地提高了焊接速度；
2.不旋转的随动轴肩可阻止塑性材料外溢，实现了焊缝的无减薄焊接，提高接头承载面积；
3.随动轴肩的加热过程作用于整个焊接过程，提高了聚合物材料的结晶度并改善组织状态；
4.根据焊接工况的不同，随动轴肩的形状可调为方形或圆形等，实现任意倾角下的直线或曲线的焊接；
5.加热后的随动轴肩不仅可预热焊缝，同时也对焊缝周围材料进行预热，降低温度梯度并改善残余应力的分布状态；
6.本发明设计简单、更换灵活、自适应和可实施性强，能够满足任意厚度板材的连接要求；
7.本发明焊接峰值温度低，可避免传统熔焊连接产生的气泡和材料降解等问题，接头强度高，而且无弧光、烟尘等对人有害的物质产生，是一种绿色、高质、高效的新方法。
附图说明
图1为本发明所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法示意图
1：搅拌头，1-1：搅拌头轴肩，1-2：搅拌针，2：随动轴肩，3：加热装置，4：金属材料板材，5：聚合物材料板材
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地阐述。
参见图1说明本实施方式，一种适用于金属与聚合物之间的搅拌摩擦焊接方法，它包括以下步骤：
步骤一：进行焊前清理，使用有机溶剂或清洗剂对待焊板材进行擦拭，去除表面杂物，所述待焊板材为聚合物材料板材5和金属材料板材4；
步骤二：使用工装夹具对待焊板材进行装夹，使待焊板材对接面相互靠近，采用聚合物材料板材5位于上层，金属材料板材4位于下层的配置原则；
步骤三：采用机械连接的方式，将随动轴肩2安装在搅拌摩擦焊机上，所述随动轴肩2嵌套在搅拌头1外侧，所述随动轴肩2底面与搅拌头轴肩1-1平齐，所述随动轴肩2内部设置有加热装置3，所述随动轴肩2跟随搅拌头1做同步平面运动；
步骤四：开启加热装置3对随动轴肩2进行加热，驱动搅拌头1旋转使搅拌针1-2下扎至待焊板材中，直至随动轴肩2底面与聚合物材料板材5上表面紧密接触时停止下扎；
步骤五：随动轴肩2对待焊板材充分预热后，驱动搅拌头1以设定焊接速度向前运动进行焊接，随动轴肩2保持加热状态并跟随搅拌头1向前运动对待焊板材进行预热，当达到焊接距离后，搅拌头1向上抬起，关闭加热装置3，完成焊接过程。
本发明使用酒精或丙酮等有机溶剂或清洗剂对待焊板材进行擦拭，去除油污和金属粉尘等杂物，使用工装夹具对待焊板材进行装夹，使待焊板材对接面相互靠近，尽可能消除对接面间隙，采用聚合物材料板材5位于上层，金属材料板材4位于下层的配置原则，采用机械连接的方式，将随动轴肩2安装在搅拌摩擦焊机上，所述随动轴肩2嵌套在搅拌头1外侧，所述随动轴肩2底面与搅拌头轴肩1-1平齐，根据待焊板材的化学和物理性能的不同，所述随动轴肩2的材质为钢、铜合金或钨铼合金，所述随动轴肩2内部设置有加热装置3，根据焊接工况的不同，所述加热装置3的加热方式为热棒、热风或火焰辅助加热，根据所需加热速度的不同，所述随动轴肩2与加热装置3为一体式结构或分体式机构，根据待焊聚合物熔点差异的不同，所述加热装置3对随动轴肩2的加热温度为聚合物材料板材5熔点的10-100％，所述随动轴肩2跟随搅拌头1做同步平面运动，所述随动轴肩2不发生旋转，开启加热装置3对随动轴肩2进行加热，驱动搅拌头1旋转使搅拌针1-2下扎至待焊板材中，直至随动轴肩2底面与聚合物材料板材5上表面紧密接触时停止下扎，停留一段时间，使随动轴肩2对待焊板材充分预热后，驱动搅拌头1以设定焊接速度向前运动进行焊接，随动轴肩2保持加热状态并跟随搅拌头1向前运动对待焊板材进行预热，当达到焊接距离后，搅拌头1向上抬起，关闭加热装置3，完成焊接过程。
以上对本发明所提供的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，进行了详细介绍，本文中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处，综上所述，本说明书内容不应理解为对本发明的限制。

Claims (8)

1.一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：它包括以下步骤：
步骤一：进行焊前清理，使用有机溶剂或清洗剂对待焊板材进行擦拭，去除表面杂物，所述待焊板材为聚合物材料板材(5)和金属材料板材(4)；
步骤二：使用工装夹具对待焊板材进行装夹，使待焊板材对接面相互靠近，采用聚合物材料板材(5)位于上层，金属材料板材(4)位于下层的配置原则；
步骤三：采用机械连接的方式，将随动轴肩(2)安装在搅拌摩擦焊机上，所述随动轴肩(2)嵌套在搅拌头(1)外侧，所述随动轴肩(2)底面与搅拌头轴肩(1-1)平齐，所述随动轴肩(2)内部设置有加热装置(3)，所述随动轴肩(2)跟随搅拌头(1)做同步平面运动；
步骤四：开启加热装置(3)对随动轴肩(2)进行加热，驱动搅拌头(1)旋转使搅拌针(1-2)下扎至待焊板材中，直至随动轴肩(2)底面与聚合物材料板材(5)上表面紧密接触时停止下扎；
步骤五：随动轴肩(2)对待焊板材充分预热后，驱动搅拌头(1)以设定焊接速度向前运动进行焊接，随动轴肩(2)保持加热状态并跟随搅拌头(1)向前运动对待焊板材进行预热，当达到焊接距离后，搅拌头(1)向上抬起，关闭加热装置(3)，完成焊接过程。
2.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述有机溶剂为酒精或丙酮。
3.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述随动轴肩(2)与加热装置(3)为一体式结构或分体式机构。
4.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述随动轴肩(2)的材质为钢、铜合金或钨铼合金。
5.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述加热装置(3)的加热方式为热棒、热风或火焰辅助加热。
6.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述随动轴肩(2)形状为平面形结构或曲面形结构。
7.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述加热装置(3)对随动轴肩(2)的加热温度为聚合物材料板材(5)熔点的10-100％。
8.根据权利要求1所述的一种适用于金属与聚合物之间的搅拌摩擦焊接方法，其特征在于：所述搅拌头(1)的旋转速度为200-1000rpm，焊接速度为5-1000mm/min，所述搅拌头轴肩(1-1)倾角为0-5度。
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